Composite pre-formed construction articles

ABSTRACT

A composite building panel that includes a central body, substantially parallelepipedic in shape, containing an expanded polymer matrix, having opposite faces, a top surface, and a bottom surface; at least one embedded framing stud longitudinally extending across the central body between the opposite faces, having a first end embedded in the expanded polymer matrix, a second end extending away from the bottom surface of the central body, and one or more expansion holes in the embedded studs between the first end of the embedded stud and bottom surface through which the polymer matrix expands. A concrete layer can optionally cover a portion of the top surface and/or bottom surface. The building panel can be positioned perpendicular to a structural wall and/or foundation to provide a floor panel. The second end of the framing studs can be embedded in a second central body to provide an insulated concrete form.

REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.11/361,189 filed Feb. 24, 2006 entitled “Composite pre-formedconstruction articles”, which claims the benefit of priority of U.S.Provisional Application Ser. Nos. 60/656,596 filed Feb. 25, 2005 and60/664,120 filed Mar. 22, 2005, both entitled “Composite Pre-FormedBuilding Panels” and U.S. Provisional Application Ser. No. 60/728,839filed Oct. 21, 2005 entitled “Composite Pre-Formed Insulated ConcreteForms,” which are all herein incorporated by reference in theirentirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to pre-formed building andconstruction panels that include one or more reinforcing structuralelements embedded in a foamed thermoplastic matrix as well as insulatedconcrete forms with internal blocking and bracing elements.

2. Description of the Prior Art

It is known to use construction elements made of expanded plastics, forexample expanded polystyrene, in forms of boards or section members ofsuitable shape and size. These members provide thermal and soundinsulation functions and have long been accepted by the buildingindustry.

It is also known that, in order to confer adequate self-supportingproperties to such construction elements, one or more reinforcingsection bars of a suitable shape must be incorporated into the mass ofexpanded plastics.

U.S. Pat. Nos. 5,787,665 and 5,822,940 discloses a molded composite wallpanels for building construction that includes a regular tetragonal bodyof polymer foam and at least one light metal gauge hollow stud in thebody. The edges of the studs are even with a surface of the polymer foamso drywall can be attached thereto.

U.S. Pat. No. 6,098,367 discloses a constructive system applied tobuildings to form walls by means of modular foldable frames that allowfor the placement of blocks or plates. The frames with the resistantchannels, rods, blocks or plates, resist better strong winds and seismicmovements.

U.S. Pat. No. 6,167,624 discloses a method for producing a polymericfoamed material panel including the steps of providing a polymericfoamed material, cutting the polymeric foamed material until reaching apreconfiguration cut point, cutting subsequently from thepreconfiguration cut point a brace-receiving configuration in thepolymeric foamed material, and sliding a brace member into thebrace-receiving configuration to produce a polymeric foamed materialpanel.

U.S. Pat. No. 6,235,367 discloses a molded construction product, havingone or more walls and an inner core section, including a compositionmatrix having a resin system, a catalytic agent, and filler compoundsfor forming the walls; a foam core system for forming the inner coresection, a curing agent and a drying agent. A structural reinforcementsupport system is provided for reinforcing the structural integrity ofthe composition. A locking system is provided for joining one or more ofthe molded products.

EP 0 459 924 discloses a self-supporting construction element made ofexpanded plastics material, specifically a floor element, which includesa substantially parallelepipedic central body in which a reinforcingsection bar, made of a thin metal sheet shaped as an I-beam, isintegrated during the molding step.

U.S. Pat. No. 5,333,429 discloses a composite panel with a structuralload-bearing wooden framework formed by a substantially parallelepipedbody of expanded synthetic material. The panels have a plurality oflongitudinal channels extending for the whole height of the panel. Aseries of channels uniformly spaced and staggered are open on theadjacent face of the panel and have a T-shaped cross section. In theseopen channels fit T-shaped cross section wooden posts, the stem portionof which emerges out of the open channels and project from the surfaceof the panel.

WO 2002/035020 discloses a composite construction element that includesa body made of expanded plastics material and a slab-shaped coatingelement associated to the body. The slab-shaped coating element includesa plurality of substantially adjoining and substantially U-shapedadjacent sections provided with respective means for mechanicallyclinching the slab-shaped element to the expanded plastics material.

While the construction elements described above have on the one hand alight weight, a comparative ease of installation and a low cost, on theother hand their application in the art and flexibility of use have beenrestrained heretofore by their poor fire-resisting properties and/or thepropensity for mold to grow on finished surfaces attached thereto.

This inadequate resistance to fire is essentially related to the factthat construction elements made of expanded plastics show aninsufficient capability to securely hold outer covering layers, such asthe plaster layers used for the outer surface finish or contain theexpanded polymer body, in flammable molten or liquid form, that occursfrom the heat generated from a fire.

When exposed to fire, in fact, the expanded plastics soon shrink into ashapeless mass of reduced volume, which can flow and burn, and in somecases with the ensuing separation of the outer covering layers and rapidcollapse of the whole structure.

In addition, an undesirable separation of the outer covering layers maybe caused in some instances by a premature “aging” of the plasticssurface to which these coverings adhere, a separation which may befurther fostered by exposure to heat sources, dusts, fumes, vapors, orchemical substances coming from a source close to the constructionelements.

U.S. Pat. No. 6,298,622 and WO 2004/101905 disclose an approach toovercoming the above-described problem by using a self-supportingconstruction element of expanded plastics for use as floor elements andwalls of buildings. The construction elements include a central body,substantially parallelepipedic in shape and having two opposite faces;at least one reinforcing section bar transversally extending across thecentral body between the faces thereof and embedded in the expandedplastics; a lath for supporting at least one layer of a suitablecovering material, associated to a fin of the reinforcing section barlying flush with and substantially parallel to at least one of the facesof the construction element. However, moisture buildup between the lathand construction element can lead to mold and mildew growth and theability to easily run electrical lines without cutting into theconstruction elements have limited the desirability of this approach.

Concrete walls in building construction are most often produced by firstsetting up two parallel form walls and pouring concrete into the spacebetween the forms. After the concrete hardens, the builder then removesthe forms, leaving the cured concrete wall.

This prior art technique has drawbacks. Formation of the concrete wallsis inefficient because of the time required to erect the forms, waituntil the concrete cures, and take down the forms. This prior arttechnique, therefore, is an expensive, labor-intensive process.

Accordingly, techniques have developed for forming modular concretewalls, which use a foam insulating material. The modular form walls areset up parallel to each other and connecting components hold the twoform walls in place relative to each other while concrete is pouredthere between. The form walls, however, remain in place after theconcrete cures. That is, the form walls, which are constructed of foaminsulating material, are a permanent part of the building after theconcrete cures. The concrete walls made using this technique can bestacked on top of each other many stories high to form all of abuilding's walls. In addition to the efficiency gained by retaining theform walls as part of the permanent structure, the materials of the formwalls often provide adequate insulation for the building.

Although the prior art includes many proposed variations to achieveimprovements with this technique, drawbacks still exist for each design.The connecting components used in the prior art to hold the walls areconstructed of (1) plastic foam, (2) high density plastic, or (3) ametal bridge, which is a non-structural support, i.e., once the concretecures, the connecting components serve no function. Even so, thesemembers provide thermal and sound insulation functions and have longbeen accepted by the building industry.

Thus, current insulated concrete form technology requires the use ofsmall molded foam blocks normally 12 to 24 inches in height with astandard length of four feet. The large amount of horizontal andvertical joints that require bracing to correctly position the blocksduring a concrete pour, restricts their use to shorter wall lengths andlower wall heights. Wall penetrations such as windows and doors requireskillfully prepared and engineered forming to withstand the pressuresexerted upon them during concrete placement. Plaster finishing crewshave difficulty hanging drywall on such systems due to the problem oflocating molded in furring strips. The metal or plastic furring stripsin current designs are non-continuous in nature and are normallyembedded within the foam faces. The characteristics present in currentblock forming systems require skilled labor, long lay-out times,engineered blocking and shoring and non-traditional finishing skills.This results in a more expensive wall that is not suitable for largerwall construction applications. The highly skilled labor force that isrequired to place, block, shore and apply finishes in a block systemseriously restricts the use of such systems when compared to traditionalconcrete construction techniques.

One approach to solving the problem of straight and true walls on largerlayouts has been to design larger blocks. Current existing manufacturingtechnology has limited this increase to 24 inches in height and eightfeet in length. Other systems create hot wire cut opposing foamedplastic panels mechanically linked together in a secondary operationutilizing metal or plastic connectors. These panels are normally 48inches in width and 8 feet in height and do not contain continuousfurring strips.

However, none of the approaches described above adequately address theproblems of form blowout at higher wall heights due to pressure exertedby the poured concrete, fast and easy construction with an unskilledlabor force, and ease of finishing the walls with readily ascertainableattachment points.

Thus there is a need in the art for composite pre-formed building panelsand insulated concrete forms with internal blocking and bracing elementsthat overcome the above-described problems.

SUMMARY OF THE INVENTION

The present invention provides a composite building panel that includes:

-   -   a central body, substantially parallelepipedic in shape, that        contains an expanded polymer matrix, having opposite faces, a        top surface, and an opposing bottom surface;    -   at least one embedded framing stud longitudinally extending        across the central body between the opposite faces, having a        first end embedded in the expanded polymer matrix, a second end        extending away from the bottom surface of the central body, and        one or more expansion holes located in the embedded studs        between the first end of the embedded studs and the bottom        surface of the central body, where, the central body contains a        polymer matrix that expands through the expansion holes; and    -   a concrete layer covering at least a portion of the top surface        and/or bottom surface.

The present invention also provides a composite floor panel thatincludes:

-   -   a central body, substantially parallelepipedic in shape,        containing an expanded polymer matrix, having opposite faces, a        top surface, and an opposing bottom surface; and    -   one or more embedded floor joists longitudinally extending        across the central body between the opposite faces, having a        first end embedded in the expanded polymer matrix having a first        transverse member extending from the first end generally        contacting or extending above the top surface, a second end        extending away from the bottom surface of the central body        having a second transverse member extending from the second end,        and one or more expansion holes located in the embedded studs        between the first end of the embedded studs and the bottom        surface of the central body;    -   where, the central body contains a polymer matrix that expands        through the expansion holes;    -   where the space defined by the bottom surface of the central        body and the second ends of the embedded joists is adapted for        accommodating utility lines; and    -   where the composite floor panel is positioned generally        perpendicular to a structural wall and/or foundation.

The present invention further provides an insulated concrete form thatincludes:

-   -   a first body, substantially parallelepipedic in shape, that        includes an expanded polymer matrix, having opposite faces, a        first surface, and an opposing second surface;    -   a second body, substantially parallelepipedic in shape, that        includes an expanded polymer matrix, having opposite faces, a        first surface, an opposing second surface; and    -   one or more embedded studs longitudinally extending across the        first body and the second body between the first surfaces of        each body, having a first end embedded in the expanded polymer        matrix of the first body, and a second end embedded in the        expanded polymer matrix of the second body, one or more        expansion holes located in the portion of the embedded studs        embedded in the first body and the second body;    -   where, the first body and the second body contain a polymer        matrix that expands through the expansion holes; and the space        defined between the first surfaces of the first body and the        second body is capable of accepting concrete poured therein.

The present invention additionally provides an insulated concrete formsystem that includes a plurality of the above described insulatedconcrete forms where at least one of an outer lip or an inner lip ofeach insulated concrete form forms a joint with another insulatedconcrete form.

The present invention is further directed to buildings that contain oneor more of the above-described insulated building panels, floor panels,insulated concrete forms and insulated concrete form systems.

The present invention is additionally directed to a method ofconstructing a building that includes:

-   -   assembling the composite building panels described above on a        generally flat surface, and    -   lifting a first end of the composite building panel while a        second end remains stationary resulting in orienting the        building panel to form a wall of the building.

The present invention is also directed to a building constructedaccording to the above-described method.

DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a cross-sectional view of a pre-formed building panelaccording to the invention;

FIG. 2 shows a side elevation view of a pre-formed building panelaccording to the invention;

FIG. 3 shows a perspective view of a construction method according tothe invention;

FIG. 4 shows a partial perspective view of a level track according tothe invention;

FIG. 5 shows a rear elevation view of a wall system according to theinvention;

FIG. 6 shows a front perspective view of a wall system according to theinvention;

FIG. 7 shows a rear side perspective view of a wall system according tothe invention;

FIG. 8 shows an expanded perspective view of a portion of the wallsystem of FIG. 7;

FIG. 9 shows a perspective view of a wall system according to theinvention;

FIG. 10 shows a partial top perspective view of a molding attached to apre-formed building panel according to the invention;

FIG. 11 shows a cross-sectional view of the molding in FIG. 10;

FIG. 12 shows a cross-sectional view of a pre-formed building panelaccording to the invention;

FIG. 13 shows a perspective view of a floor system according to theinvention; and

FIG. 14 shows a perspective view of a floor system according to theinvention;

FIG. 15 shows a cross-sectional view of a pre-formed building panelaccording to the invention;

FIG. 16 shows a cross-sectional view of a pre-formed building panelaccording to the invention;

FIG. 17 shows a cross-sectional view of a concrete composite pre-formedbuilding panel system according to the invention;

FIG. 18 shows a cross-sectional view of a pre-formed building panelaccording to the invention;

FIG. 19 shows a perspective view of a metal stud used in the invention;

FIG. 20 shows a cross-sectional view of a concrete composite pre-formedbuilding panel system according to the invention;

FIG. 21 shows a cross-sectional view of a concrete composite pre-formedbuilding panel system according to the invention;

FIG. 22 shows a cross-sectional view of a pre-formed building panelaccording to the invention;

FIG. 23 shows a perspective view of a metal stud used in the invention;

FIG. 24 shows a cross-sectional view of a concrete composite pre-formedbuilding panel system according to the invention;

FIG. 25 shows a cross-sectional view of a concrete composite pre-formedbuilding panel system according to the invention;

FIGS. 26, 27, and 28 show a cross-sectional view of metal studs that canbe used in the pre-formed building panels according to the invention;

FIG. 29 shows a partial elevation view of a pre-formed building panelaccording to the invention;

FIG. 30 shows a top plan view of a pre-formed insulated concrete formaccording to the invention;

FIG. 31 shows a top plan view of a pre-formed insulated concrete formaccording to the invention;

FIG. 32 shows a cross-sectional view of a pre-formed insulated concreteform according to the invention;

FIG. 33 shows a partial perspective view of an embedded stud used in theinvention;

FIG. 34 shows a perspective view of a pre-formed insulated concrete formaccording to the invention;

FIG. 35 shows a perspective view of the concrete and embedded studportion of an insulated concrete form according to the invention;

FIG. 36 shows a perspective view of the concrete and a embedded studportion of an insulated concrete form according to the invention;

FIG. 37 shows a partial perspective view of a metal stud used in theinvention;

FIG. 38 shows a plan view of an insulated concrete form system accordingto the invention;

FIG. 39 shows an insulated concrete form corner unit according to theinvention; and

FIG. 40 illustrates a manufacturer/customer method of designing customcomposite building panels according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

For the purpose of the description hereinafter, the terms “upper,”“lower,” “inner”, “outer”, “right,” “left,” “vertical,” “horizontal,”“top,” “bottom,” and derivatives thereof, shall relate to the inventionas oriented in the drawing Figures. However, it is to be understood thatthe invention may assume alternate variations and step sequences exceptwhere expressly specified to the contrary. It is also to be understoodthat the specific devices and processes, illustrated in the attacheddrawings and described in the following specification, is an exemplaryembodiment of the present invention. Hence, specific dimensions andother physical characteristics related to the embodiment disclosedherein are not to be considered as limiting the invention. In describingthe embodiments of the present invention, reference will be made hereinto the drawings in which like numerals refer to like features of theinvention.

Other than where otherwise indicated, all numbers or expressionsreferring to quantities, distances, or measurements, etc. used in thespecification and claims are to be understood as modified in allinstances by the term “about.” Accordingly, unless indicated to thecontrary, the numerical parameters set forth in the followingspecification and attached claims are approximations that can varydepending upon the desired properties, which the present inventiondesires to obtain. At the very least, and not as an attempt to limit theapplication of the doctrine of equivalents to the scope of the claims,each numerical parameter should at least be construed in light of thenumber of reported significant digits and by applying ordinary roundingtechniques.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope of the invention are approximations, the numericalvalues set forth in the specific examples are reported as precisely aspossible. Any numerical values, however, inherently contain certainerrors necessarily resulting from the standard deviation found in theirrespective measurement methods.

Also, it should be understood that any numerical range recited herein isintended to include all sub-ranges subsumed therein. For example, arange of “1 to 10” is intended to include all sub-ranges between andincluding the recited minimum value of 1 and the recited maximum valueof 10; that is, having a minimum value equal to or greater than 1 and amaximum value of equal to or less than 10. Because the disclosednumerical ranges are continuous, they include every value between theminimum and maximum values. Unless expressly indicated otherwise, thevarious numerical ranges specified in this application areapproximations.

As used herein, the term “expandable polymer matrix” refers to apolymeric material in particulate or bead form that is impregnated witha blowing agent such that when the particulates and/or beads are placedin a mold and heat is applied thereto, evaporation of the blowing agent(as described below) effects the formation of a cellular structureand/or an expanding cellular structure in the particulates and/or beadsand the outer surfaces of the particulates and/or beads fuse together toform a continuous mass of polymeric material conforming to the shape ofthe mold.

As used herein, the term “polymer” is meant to encompass, withoutlimitation, homopolymers, copolymers and graft copolymers.

As used herein, the terms “(meth)acrylic” and “(meth)acrylate” are meantto include both acrylic and methacrylic acid derivatives, such as thecorresponding alkyl esters often referred to as acrylates and(meth)acrylates, which the term “(meth)acrylate” is meant to encompass.

The present invention provides pre-formed building panels that includeone or more reinforcing structural elements or bars runninglongitudinally, which are partially exposed, with the remainder of thereinforcing structural element(s) partially encapsulated in an expandedpolymer matrix, which acts as a thermal break. The reinforcingstructural elements can be flanged lengthwise on either side to provideattachment points for external objects to the panel. Perforations in thereinforcing structural elements which are encapsulated in the expandedpolymer matrix allow for fusion perpendicularly. Perforations in theexposed portion of the reinforcing structural element provide attachmentpoints for lateral bracing and utility installation. A tongue and grooveconnection point design provides for panel abutment, weep holes andattachment points for external objects. Recessed areas on opposing panelends provide an area of member-to-member connection with “C” channelsrunning along the top and bottom of the structural member. Longitudinalholes through the expanded polymer matrix are variable in diameter andlocation and provide areas for placement of utilities, lightening thestructure and channels for venting of gasses. Panel manufacture isaccomplished through the use of a semi-continuous or continuous moldingprocess allowing for variable panel lengths.

The embedded framing studs or floor joists used in the invention can bemade of any suitable material. Suitable materials are those that addstrength, stability and structural integrity to the pre-formed buildingpanels. Such materials provide embedded framing studs meeting therequirements of applicable test methods known in the art, asnon-limiting examples ASTM A 36/A 36M-05, ASTM A 1011/A 1011M-05a, ASTMA 1008/A 1008M-05b, and ASTM A 1003/A 1003M-05 for various types ofsteel.

Suitable materials include, but are not limited to metals, constructiongrade plastics, composite materials, ceramics, combinations thereof, andthe like. Suitable metals include, but are not limited to, aluminum,steel, stainless steel, tungsten, molybdenum, iron and alloys andcombinations of such metals. In a particular embodiment of theinvention, the metal bars, studs, joists and/or members are made of alight gauge metal.

Suitable construction grade plastics include, but are not limited toreinforced thermoplastics, thermoset resins, and reinforced thermosetresins. Thermoplastics include polymers and polymer foams made up ofmaterials that can be repeatedly softened by heating and hardened againon cooling. Suitable thermoplastic polymers include, but are not limitedto homopolymers and copolymers of styrene, homopolymers and copolymersof C₂ to C₂₀ olefins, C₄ to C₂₀ dienes, polyesters, polyamides,homopolymers and copolymers of C₂ to C₂₀ (meth)acrylate esters,polyetherimides, polycarbonates, polyphenylethers, polyvinylchlorides,polyurethanes, and combinations thereof.

Suitable thermoset resins are resins that when heated to their curepoint, undergo a chemical cross-linking reaction causing them tosolidify and hold their shape rigidly, even at elevated temperatures.Suitable thermoset resins include, but are not limited to alkyd resins,epoxy resins, diallyl phthalate resins, melamine resins, phenolicresins, polyester resins, urethane resins, and urea, which can becrosslinked by reaction, as non-limiting examples, with diols, triols,polyols, and/or formaldehyde.

Reinforcing materials and/or fillers that can be incorporated into thethermoplastics and/or thermoset resins include, but are not limited tocarbon fibers, aramid fibers, glass fibers, metal fibers, woven fabricor structures of the mentioned fibers, fiberglass, carbon black,graphite, clays, calcium carbonate, titanium dioxide, woven fabric orstructures of the above-referenced fibers, and combinations thereof.

A non-limiting example of construction grade plastics are thermosettingpolyester or vinyl ester resin systems reinforced with fiberglass thatmeet the requirements of required test methods known in the art,non-limiting examples being ASTM D790, ASTM D695, ASTM D3039 and ASTMD638.

The thermoplastics and thermoset resins can optionally include otheradditives, as a non-limiting example ultraviolet (UV) stabilizers, heatstabilizers, flame retardants, structural enhancements, biocides, andcombinations thereof.

The embedded framing studs or embedded floor joists (reinforcingembedded bars) can have a thickness of at least 0.4 mm, in some cases atleast 0.5 mm, in other cases at least 0.75 mm, in some instances atleast 1 mm, in other instances at least 1.25 mm and in somecircumstances at least 1.5 mm and can have a thickness of up to 10 mm,in some cases up to 8 mm, in other cases up to 6 mm, in some instancesup to 4 mm and in other cases up to 2 mm. The thickness of the embeddedframing studs or embedded floor joists will depend on the intended useof the pre-formed building panel.

In an embodiment of the invention, the embedded reinforcing bars, studs,joists and/or members have holes or openings along their length tofacilitate fusion of the expanded plastic material and to reduce anythermal bridging effects in the reinforcing bars, studs, joists and/ormembers.

The expanded polymer matrix makes up the expanded polymer body describedherein below. The expanded polymer matrix is typically molded fromexpandable thermoplastic particles. These expandable thermoplasticparticles are made from any suitable thermoplastic homopolymer orcopolymer. Particularly suitable for use are homopolymers derived fromvinyl aromatic monomers including styrene, isopropylstyrene,alpha-methylstyrene, nuclear methylstyrenes, chlorostyrene,tert-butylstyrene, and the like, as well as copolymers prepared by thecopolymerization of at least one vinyl aromatic monomer as describedabove with one or more other monomers, non-limiting examples beingdivinylbenzene, conjugated dienes (non-limiting examples beingbutadiene, isoprene, 1,3- and 2,4-hexadiene), alkyl methacrylates, alkylacrylates, acrylonitrile, and maleic anhydride, wherein the vinylaromatic monomer is present in at least 50% by weight of the copolymer.In an embodiment of the invention, styrenic polymers are used,particularly polystyrene. However, other suitable polymers can be used,such as polyolefins (e.g. polyethylene, polypropylene), polycarbonates,polyphenylene oxides, and mixtures thereof.

In a particular embodiment of the invention, the expandablethermoplastic particles are expandable polystyrene (EPS) particles.These particles can be in the form of beads, granules, or otherparticles convenient for the expansion and molding operations. Particlespolymerized in an aqueous suspension process are essentially sphericaland are useful for molding the expanded polymer body described hereinbelow. These particles can be screened so that their size ranges fromabout 0.008 inches (0.2 mm) to about 0.1 inches (2.5 mm).

The expandable thermoplastic particles can be impregnated using anyconventional method with a suitable blowing agent. As a non-limitingexample, the impregnation can be achieved by adding the blowing agent tothe aqueous suspension during the polymerization of the polymer, oralternatively by re-suspending the polymer particles in an aqueousmedium and then incorporating the blowing agent as taught in U.S. Pat.No. 2,983,692. Any gaseous material or material which will produce gaseson heating can be used as the blowing agent. Conventional blowing agentsinclude aliphatic hydrocarbons containing 4 to 6 carbon atoms in themolecule, such as butanes, pentanes, hexanes, and the halogenatedhydrocarbons, e.g. CFC's and HCFC'S, which boil at a temperature belowthe softening point of the polymer chosen. Mixtures of these aliphatichydrocarbon blowing agents can also be used.

Alternatively, water can be blended with these aliphatic hydrocarbonsblowing agents or water can be used as the sole blowing agent as taughtin U.S. Pat. Nos. 6,127,439; 6,160,027; and 6,242,540 in these patents,water-retaining agents are used. The weight percentage of water for useas the blowing agent can range from 1 to 20%. The texts of U.S. Pat.Nos. 6,127,439, 6,160,027 and 6,242,540 are incorporated herein byreference.

The impregnated thermoplastic particles are generally pre-expanded to adensity of at least 0.5 lb/ft³ (0.008 g/cc), in some cases at least 1lb/ft³ (0.016 g/cc), in other cases at least 1.25 lb/ft³ (0.02 g/cc), insome situations at least 1.5 lb/ft³ (0.024 g/cc), in other situations atleast 2 lb/ft³ (0.032 g/cc), and in some instances at least about 3lb/ft³ (0.048 g/cc). Also, the density of the impregnated pre-expandedparticles can be up to 35 lb/ft³ (0.56 g/cc), in some cases up to 30lb/ft³ (0.48 g/cc), and in other cases up to 25 lb/ft³ (0.4 g/cc). Thedensity of the impregnated pre-expanded particles can be any value orrange between any of the values recited above. The pre-expansion step isconventionally carried out by heating the impregnated beads via anyconventional heating medium, such as steam, hot air, hot water, orradiant heat. One generally accepted method for accomplishing thepre-expansion of impregnated thermoplastic particles is taught in U.S.Pat. No. 3,023,175.

The impregnated thermoplastic particles can be foamed cellular polymerparticles as taught in U.S. patent application Ser. No. 10/021,716, theteachings of which are incorporated herein by reference. The foamedcellular particles can be polystyrene that are pre-expanded and containa volatile blowing agent at a level of less than 6.0 weight percent, insome cases ranging from about 2.0 wt % to about 5.0 wt %, and in othercases ranging from about 2.5 wt % to about 3.5 wt % based on the weightof the polymer.

An interpolymer of a polyolefin and in situ polymerized vinyl aromaticmonomers that can be included in the expandable thermoplastic resinaccording to the invention is disclosed in U.S. Pat. Nos. 4,303,756 and4,303,757 and U.S. Application Publication 2004/0152795, the relevantportions of which are herein incorporated by reference. A non-limitingexample of interpolymers that can be used in the present inventioninclude those available under the trade name ARCEL®, available from NOVAChemicals Inc., Pittsburgh, Pa. and PIOCELAN®, available from SekisuiPlastics Co., Ltd., Tokyo, Japan.

The expanded polymer matrix can include customary ingredients andadditives, such as pigments, dyes, colorants, plasticizers, mold releaseagents, stabilizers, ultraviolet light absorbers, mold preventionagents, antioxidants, and so on. Typical pigments include, withoutlimitation, inorganic pigments such as carbon black, graphite,expandable graphite, zinc oxide, titanium dioxide, and iron oxide, aswell as organic pigments such as quinacridone reds and violets andcopper phthalocyanine blues and greens.

In a particular embodiment of the invention the pigment is carbon black,a non-limiting example of such a material being EPS SILVER®, availablefrom NOVA Chemicals Inc.

In another particular embodiment of the invention the pigment isgraphite, a non-limiting example of such a material being NEOPOR®,available from BASF Aktiengesellschaft Corp., Ludwigshafen am Rhein,Germany.

When materials such as carbon black and/or graphite are included in thepolymer particles, improved insulating properties, as exemplified byhigher R values for materials containing carbon black or graphite (asdetermined using ASTM-C578), are provided. As such, the R value of theexpanded polymer particles containing carbon black and/or graphite ormaterials made from such polymer particles are at least 5% higher thanobserved for particles or resulting articles that do not contain carbonblack and/or graphite.

The pre-expanded particles or “pre-puff” are heated in a closed mold inthe semi-continuous or continuous molding process described below toform the pre-formed building panels according to the invention.

The expanded polymer body used in the invention include holes, conduitsor chases that molded into and extend along the length of the expandedpolymer body. In an embodiment of the invention, the holes, conduits orchases are used for providing access, ways for utilities, such aswiring, plumbing and exhaust through the walls, ceilings, floors androofs constructed according to the present invention.

In another embodiment of the invention, the wall units, floor units andexpanded polymer panels or central body have a male “tongue” edge and afemale “groove” edge that facilitates a “tongue and groove” union of twomatching wall units, floor units and expanded polymer panels. The tongueand groove union can be non-linear and can provide for a weep holeand/or larger opening to accommodate plumbing lines. Typically thetongue and groove union provides a flat surface at the union to allowfor easy application of sealing tape to seal the union or joint.

An embodiment of the present invention provides wall units and wallsystems. As shown in FIG. 1, wall unit 10 includes expanded polymer body12 (central body), left facing embedded metal studs 14, and right facingembedded metal studs 16 (reinforcing embed bars). Expanded polymer body12 includes openings 18 that traverse all or part of the length ofexpanded polymer body 12. The embedded metal studs 14 and 16 haveembedded ends 20 and 22 respectively that do not touch outer surface 24of expanded polymer body 12. The embedded metal studs 14 and 16 alsohave exposed ends 26 and 28 respectively that extend from inner surface30 of expanded polymer body 12.

Expanded polymer body 12 can have a thickness 5, measured as thedistance from inner surface 30 to outer surface 24 of at least 2, insome cases at least 2.5, and in other cases at least 3 cm and can be upto 10, in some cases up to 8, and in other cases up to 6 cm from innersurface 30 of expanded polymer body 12. Embedded ends 26 and 28 canextend any of the distances or can range between any of the distancesrecited above from inner surface 30.

Exposed ends 26 and 28 extend at least 1, in some cases at least 2, andin other cases at least 3 cm away from inner surface 30 of expandedpolymer body 12. Also, Exposed ends 26 and 28 can extend up to 60, insome cases up to 40, and in other cases up to 20 cm away from innersurface 30 of expanded polymer body 12. In many cases exposed ends 26and 28 extend from polymer body 12 a distance sufficient to allowutilities to be run along inner surface 30 as described herein. Exposedends 26 and 28 can extend any of the distances or can range between anyof the distances recited above from inner surface 30.

Embedded ends 20 and 22 extend at least 1, in some cases at least 2, andin other cases at least 3 cm into expanded polymer body 12 away frominner surface 30. Also, Embedded ends 20 and 22 can extend up to 10, insome cases up to 8, and in other cases up to 6 cm away from innersurface 30 into expanded polymer body 12. In many cases, embedded ends20 and 22 extend a distance into expanded polymer body 12 such thatembedded ends 20 and 22 do not contact outer surface 24. The depthdefined between outer surface 24 and embedded ends 20 and 22 define athermal break. Embedded ends 26 and 28 can extend any of the distancesor can range between any of the distances recited above from innersurface 30 into polymer body 12.

In another embodiment of the invention, embedded ends 20 and 22 canextend from 1/10 to 9/10, in some cases ⅓ to ⅔ and in other cases ¼ to ¾of the thickness of expanded polymer body 12 into expanded polymer body12.

In an embodiment of the invention, embedded metal studs 14 and 16 have across-sectional shape that includes embedding lengths 34 and 36,embedded ends 20 and 22, and exposed ends 26 and 28. The orientation ofembedded metal studs 14 and 16 is referenced by the direction of openends 38 and 40. In an embodiment of the invention, open ends 38 and 40are oriented away from each other. In this embodiment, wall unit 10 hasgreater rigidity and is easier to handle without bending.

The spacing between each of embedded metal studs 14 and 16 is typicallyadapted to be consistent with local construction codes or methods, butcan be modified to suit special needs. As such, the spacing between themetal studs can be at least 10, in some instances at least 25 and insome cases at least 30 cm and can be up to 110, in some cases up to 100,in other cases up to 75, and in some instances up to 60 cm measured froma midpoint of exposed end 26 to a midpoint of exposed end 28. Thespacing between embedded metal studs 14 and 16 can be any distance orrange between any of the distances recited above.

Openings 18 can have various cross-sectional shapes, non-limitingexamples being round, oval, elliptical, square, rectangular, triangular,hexagonal or octagonal. The cross-sectional size of openings 18 can beuniform or they can vary independently of each other with regard to sizeand location relative to inner surface 30 and outer surface 24. Thespacing between each opening 18 can be at least 5 and in some cases atleast 10 cm and can be up to 110, in some cases up to 100, in othercases up to 75, and in some instances up to 60 cm measured from amidpoint of one opening 18 to an adjacent opening 18. The spacingbetween openings 18 can independently be any distance or range betweenany of the distances recited above.

The cross-sectional area of openings 18 can also vary independently onefrom another or they can be uniform. The cross-sectional area ofopenings 18 is limited by the dimensions of expanded polymer body 12, asopenings 18 will fit within the dimensions of expanded polymer body 12.The cross-sectional area of openings 18 can independently be at least 1,in some cases at least 5, and in other cases at least 9 cm² and can beup to 130, in some cases up to 100, in other cases up to 75 cm². Thecross-sectional area of openings 18 can independently be any value orrange between any of the values recited above.

As shown in FIG. 1, expanded polymer body 12 can extend for a distancewith alternating embedded metal studs 14 and 16 placed therein. Thelength of wall unit 10 can be any length that allows for safe handlingand minimal damage to wall unit 10. The length of wall unit 10, definedas the distance from receiving end 27 to male terminal end 21, cantypically be at least 1, in some cases at least 1.5, and in other casesat least 2 m and can be up to 25, in some cases up to 20, in other casesup to 15, in some instances up to 10 and in other instances up to 5 m.The length of wall unit 10 can be any value or can range between any ofthe values recited above. In some embodiments of the invention, each endof wall unit 10 is terminated with an embedded metal stud.

The height of wall unit 10 can be any height that allows for safehandling and minimal damage to wall unit 10. The height of wall unit 10is determined by the length of embedded metal studs 14 and 16. Theheight of wall unit 10 can be at least 1 and in some cases at least 1.5m and can be up to 3 M and in some cases up to 2.5 m. In some instances,in order to add stability to wall unit 10, reinforcing cross-members(not shown) can be attached to embedded metal studs 14 and 16. Theheight of wall unit 10 can be any value or can range between any of thevalues recited above.

As shown in FIG. 1, expanded polymer body 12 has a finite length 72 andhas a male terminal end 21 that includes forward edge 23 and trailingedge 25 and a receiving end 27 which includes recessed section 29 andextended section 31, which is adapted to receive forward edge 23, andtrailing edge 25. Typically, lengths of wall units 10 are interconnectedby inserting a forward edge 23 from a first wall unit 10 into a recessedsection 29 a second wall unit 10. In this manner, a larger wall sectioncontaining any number of wall units can be assembled and/or arrayed.

Wall unit 10 is typically part of an overall wall system 21 as shown inFIGS. 3-11. A bottom end of embedded metal studs 14 and 16 are seated inand attached to a bottom track 44 and a top slip track 42. Thisconfiguration leads to the formation of bottom channel 52 and topchannel 54. Channels 52 and 54 can be filled with correspondingly shapedexpanded polymer material, or alternatively with a molding shaped to fitin channels 52 or 54.

As a non-limiting example molding 58 can be inserted into top channel 54and attached to top slip track 42 by inserting fasteners 60 into holes62 in top slip track 62 as shown in FIGS. 10 and 11. Molding 58 providesa thermal break to the exposed metal track.

Channels 52 and 54 provide an advantageous feature of the presentinvention as the channels at the ends of the panels expose the embeddedmetal studs 14 and 16 on both sides. This feature over comes a basicstructural problem in the prior art by providing a positive mechanicalconnection to both sides of the embedded metal studs when top slip track42 and bottom track 44 are installed.

Referring to FIGS. 3, 5, and 7-9, embedded metal studs 14 and 16 canhave utility holes 46 spaced along their length. Utility holes 46 areuseful for accommodating utilities such as wiring for electricity,telephone, cable television, speakers, and other electronic devices, gaslines and water lines (as shown particularly in FIG. 9). Utility holes46 can have various cross-sectional shapes, non-limiting examples beinground, oval, elliptical, square, rectangular, triangular, hexagonal oroctagonal. The cross-sectional area of Utility holes 46 can also varyindependently one from another or they can be uniform. Thecross-sectional area of utility holes 46 is limited by the dimensions ofembedded metal studs 14 and 16, as utility holes 46 will fit withintheir dimensions and not significantly detract from their structuralintegrity and strength. The cross-sectional area of utility holes 46 canindependently be at least 1, in some cases at least 2, and in othercases at least 5 cm² and can be up to 30, in some cases up to 25, inother cases up to 20 cm². The cross-sectional area of openings 18 canindependently be any value or range between any of the values recitedabove.

In an embodiment of the invention, utility holes 46 can have a flangedand in many cases a rolled flange surface to provided added strength tothe embedded metal studs. The flanged holes allow for the use of lightergauge materials to achieve the same structural properties.

A wall system 21 is shown in FIGS. 5-8, where three wall units areconnected. Where the ends of two wall units meet to form a corner, anoutside corner attachment 47 secures the ends of the two wall unitstogether. Also, additional metal studs 49 can be included to addstrength to the formed corners. Thus the wall system includesinterconnecting bottom 44 and top 42 slip tracks and end embedded metalstuds 51 secured together at corner attachment units that extend alongthe height of each wall unit.

Openings for windows and doors are provided by framing the ends of theopening with two or more embedded metal studs placed adjacent to eachother (shown as 53). Upper member 55 and lower member 57 are connectedto the embedded metal studs to form a framed opening. The openings areadapted to readily accept pre-manufactured windows and doors.

The strength and integrity of wall system 21 can be enhanced byincluding spanner bars 61 that are arranged to pass through openings,such as utility holes 46 in embedded metal studs 14 and 16. Spanner bars61 are attached to embedded metal studs 14 and 16 and are arranged, asshown, in a generally perpendicular relationship to metal studs 14 and16, although spanner bars 61 can be arranged to form any suitable anglewith embedded metal studs 14 and 16 that enhances the strength andintegrity or wall system 21. Spanner bars and metal studs that can beincorporated in the invention include those available under the tradename TRADEREADY® SPAZZER® available from Dietrich Industries, Inc.,Pittsburgh, Pa. as well as those disclosed in U.S. Pat. Nos. 5,784,850and 6,021,618, the relevant portions of which are herein incorporated byreference.

The various metal structural parts in wall system 21 can be secured orattached to one another by way of welds 71 and/or screws 73.

Particular advantages of the present wall units and wall systems includethe ability to easily run utilities prior to attaching a finish surfaceto the exposed ends of the embedded metal studs. The exposed metal studsfacilitate field structural framing changes and additions and leave thestructural portions of the assembly exposed for local building officialsto inspect the framing.

Referring to FIG. 9, in an embodiment of the invention, wall unit 10includes expanded polymer body 12 (central body), right facing embeddedmetal studs 16 (reinforcing embed bars), which include flanges 11 andhave utility holes 46 located in an exposed portion of embedded studs16, expansion holes 13 in an embedded portion of embedded studs 16 andembedded end 22, which, does not touch outer surface 24 of expandedpolymer body 12. The embedded metal studs 16 also have exposed end 28respectively that extends from inner surface 30 of expanded polymer body12.

Expansion holes 13 are useful in that as expanded polymer body 12 ismolded, the polymer matrix expands through expansion holes 13 and theexpanding polymer fuses. This allows the polymer matrix to encase andhold embedded studs 16 by way of the fusion in the expanding polymer. Inan embodiment of the invention, expansion holes 13 can have a flangedand in many cases a rolled flange surface to provided added strength tothe embedded metal studs.

A utility space defined by inner surface 30 of expanded polymer body 12and flanges 11 adapted for accommodating utilities is provided.Typically, flanges 11 have a finish surface (as described herein)attached to them, a side of which further defines the utility space.

In an embodiment of the invention, the utility space is adapted anddimensioned to receive standard and/or pre-manufactured components, suchas windows, doors and medicine cabinets as well as customized cabinetsand shelving.

In an embodiment of the invention, utility holes 46 are adapted to allowutilities (as shown, electrical line 15) to be run in a transversedirection relative to embedded studs 16.

The utilities can be one or more selected from water lines (eitherpotable, or as a non-limiting example hot water lines for radiantheating), waste lines, chases, telephone lines, cable television lines,computer lines, fiber optic cables, satellite dish communication lines,antenna lines, electrical lines, ductwork, and gas lines.

In a particular embodiment of the invention, wall unit 10 is attached tobottom track 44. In this embodiment, bottom track 44 is adapted to holda volume at least equivalent to the volume of the expanded polymermatrix in expanded polymer body 12, in liquid or molten form. In someinstances, this volume can be defined by bottom 101 and sides 103 ofbottom track 44 and the portions of embedded studs 16 within the spacedefined by bottom track 44.

Non-limiting examples of suitable finish surfaces include wood, rigidplastics, wood paneling, concrete panels, cement panels, drywall,sheetrock, particle board, rigid plastic panels, a metal lath,combinations thereof or any other suitable material having decoratingand/or structural functions.

Further, the air space between the inner surface of the expanded polymerbody and the finish surface allows for improved air circulation, whichcan minimize or prevent mildew. Additionally, because the metal studsare not in direct contact with the outer surface, thermal bridging viathe highly conductive embedded metal studs is avoided and insulationproperties are improved.

The present invention also provides floor units and floor systems thatinclude composite floor panels. The floor panels generally include acentral body, substantially parallelepipedic in shape, containing anexpanded polymer matrix, having opposite faces, a top surface, and anopposing bottom surface; and two or more embedded floor joistslongitudinally extending across the central body between the oppositefaces, having a first end embedded in the expanded polymer matrix,having a first transverse member extending from the first end generallycontacting or extending above the top surface, a second end extendingaway from the bottom surface of the central body having a secondtransverse member extending from the second end, and one or moreexpansion holes located in the embedded floor joists between the firstend of the embedded floor joists and the bottom surface of the centralbody. The central body contains a polymer matrix as described above thatexpands through the expansion holes. The embedded floor joists includeone or more utility holes located in the embedded joists between thebottom surface of the central body and the second end of the embeddedjoists and the space defined by the bottom surface of the central bodyand the second ends of the embedded floor joists is adapted foraccommodating utility lines. The composite floor panel is positionedgenerally perpendicular to a structural wall and/or foundation.

As shown in FIG. 12, floor unit 90 includes expandable polymer panel 92(central body) and embedded metal joists 94 and 96 (reinforcing embeddedbars). Expandable polymer panel 92 includes openings 98 that traverseall or part of the length of expanded polymer panel 92. The embeddedmetal joists 94 and 96 have embedded ends 104 and 106 respectively thatare in contact with top surface 102 of expanded polymer panel 92. Theembedded metal joists 94 and 96 also have exposed ends 108 and 110respectively that extend from bottom surface 100 of expanded polymerpanel 92.

Embedded metal joists 94 and 96 include first transverse members 124 and126 respectively extending from embedded ends 104 and 106 respectively,which are generally in contact with top surface 102 and exposed ends 108and 110 include second transverse members 128 and 129 respectively,which extend from exposed ends 108 and 110 respectively. The spacedefined by bottom surface 100 of expanded polymer panel 92 and theexposed ends 108 and 110 and second transverse members 128 and 129 ofembedded metal joists 94 and 96 can be oriented to accept ductworkplaced between embedded metal joists 94 and 96 adjacent bottom surface100.

Expanded polymer panel 92 can have a thickness, measured as the distancefrom top surface 102 to bottom surface 100 similar in dimensions to thatdescribed above regarding expanded polymer body 12.

Exposed ends 108 and 110 extend at least 1, in some cases at least 2,and in other cases at least 3 cm away from bottom surface 100 ofexpanded polymer panel 92. Also, Exposed ends 108 and 110 can extend upto 60, in some cases up to 40, and in other cases up to 20 cm away frombottom surface 100 of expanded polymer panel 92. Exposed ends 108 and110 can extend any of the distances or can range between any of thedistances recited above from bottom surface 100.

In an embodiment of the invention, embedded metal joists 94 and 96 havea cross-sectional shape that includes embedding lengths 114 and 116,embedded ends 104 and 106, and exposed ends 108 and 110. The orientationof embedded metal joists 94 and 96 is referenced by the direction ofopen ends 118 and 120. In an embodiment of the invention, open ends 118and 120 are oriented toward each other. In this embodiment, floor unit90 is adapted to accept ductwork. As a non-limiting example, a HVAC ductcan be installed along the length of embedded metal joists 94 and 96.

As used herein, the term “ductwork” refers to any tube, pipe, channel orother enclosure through which air can flow from a source to a receivingspace; non-limiting examples being air flowing from heating and/orair-conditioning equipment to a room, make-up air flowing from a room toheating and/or air-conditioning equipment, fresh air flowing to anenclosed space, and/or waste air flowing from an enclosed space to alocation outside of the enclosed space. In some embodiments, ductworkincludes generally rectangular metal tubes that are located below andextend generally adjacent to a floor.

The spacing between each of embedded metal joists 94 and 96 can be asdescribed regarding embedded metal studs 14 and 16 in wall unit 10.

Openings 98 can have various cross-sectional shapes, and similar spacingand cross-sectional area as described regarding openings 18 in expandedpolymer body 12.

As shown in FIG. 12, expanded polymer panel 92 can extend for a distancewith alternating embedded metal joists 94 and 96 placed therein. Thelength of floor unit 90 can be any length that allows for safe handlingand minimal damage to floor unit 90. The length of floor unit 90 can beas described regarding the length of wall unit 10. In some embodiments,an end of floor unit 90 can be terminated with an embedded metal joist.

As shown in FIG. 12, expanded polymer panel 92 has a finite length andhas a male terminal end 91 that includes forward edge 93 and trailingedge 95 and a receiving end 97 which includes recessed section 99 andextended section 101, which is adapted to receive forward edge 93, andtrailing edge 95. Typically, lengths of floor units 90 areinterconnected by inserting a forward edge 93 from a first floor unit 90into a recessed section 99 from a second floor unit 90. In this manner,a larger floor section containing any number of floor units can beassembled and/or arrayed.

The width of floor unit 90 can be any width that allows for safehandling and minimal damage to floor unit 90. The width of floor unit 90is determined by the length of embedded metal joists 94 and 96. Thewidth of floor unit 90 can be at least 1 and in some cases at least 1.5m and can be up to 3 m and in some cases up to 2.5 m. In some instances,in order to add stability to floor unit 90, reinforcing cross-members(not shown) can be attached to embedded metal joists 94 and 96. Thewidth of floor unit 90 can be any value or can range between any of thevalues recited above.

Floor unit 90 is typically part of an overall floor system that includesa plurality of the composite floor panels described herein, where themale ends include a tongue edge and the female ends include a groovearrayed such that a tongue and/or groove of each panel is in sufficientcontact with a corresponding tongue and/or groove of another panel toform a plane. The established plane extends laterally from a foundationand/or a structural wall.

In the present floor system, ductwork can be attached to the reinforcingmetal bars of at least one composite floor panel.

Additionally, a flooring material can be attached to or in contact withone or more of the first transverse members of the composite floorpanels. Any suitable flooring material can be used in the invention.Suitable flooring materials are materials that can be attached to thetransverse members and cover at least a portion of the expanded polymerpanel. Suitable flooring materials include, but are not limited toplywood, wood planks, tongue and grooved wood floor sections, sheetmetal, sheets of structural plastics, stone, ceramic, cement, concrete,and combinations thereof.

Generally, the floor system forms a plane that extends laterally from afoundation and/or a structural wall.

FIGS. 13 and 14 show floor systems 140 and 141 respectively. Floorsystem 140 is established by contacting forward edge 93 with recessedsection 99 to form a continuous floor 142. Like features of theindividual floor panels are labeled as indicated above. As describedabove, various shaped types of ductwork can be secured in the spacedefined by bottom surface 100 of expanded polymer panel 92 and theexposed ends 108 and 110 and second transverse members 128 and 129 ofembedded metal joists 94 and 96. As non-limiting examples, rectangularventilation duct 147 is shown in FIG. 13 and circular air duct 148 isshown in FIG. 14. As shown in the embodiment of FIG. 13, tongue andgroove wood flooring 149 is placed over floor units 90 and attached tofirst transverse members 124 and 126. In an alternative embodiment (notshown) a plywood, plastic, particle board or other suitable sub-floorcan be attached to first transverse members 124 and 126 and tongue andgroove wood flooring 149 attached thereto.

As shown in FIG. 3, an end of embedded metal joists 94 and 96 are seatedin and attached to a joist rim 122 and a second joist rim is attached tothe other end of embedded metal joists 94 and 96. A floor base 149,typically plywood, particle board or other supporting surface orflooring material, can be attached to first transverse members 124and/or 126.

Referring to FIG. 3, embedded metal joists 94 and 96 have utility holes127 spaced along their length. Utility holes 127 are useful foraccommodating wiring for electricity, telephone, cable television,speakers, and other electronic devices. Utility holes 127 can havevarious cross-sectional shapes, non-limiting examples being round, oval,elliptical, square, rectangular, triangular, hexagonal or octagonal. Thecross-sectional area of Utility holes 127 can also vary independentlyone from another or they can be uniform. The cross-sectional area ofutility holes 127 is limited by the dimensions of embedded metal joists94 and 96, as utility holes 127 will fit within their dimensions and notsignificantly detract from their structural integrity and strength. Thecross-sectional area of utility holes 127 can independently be at least1, in some cases at least 2, and in other cases at least 5 cm² and canbe up to 30, in some cases up to 25, in other cases up to 20 cm². Thecross-sectional area of utility holes 127 can independently be any valueor range between any of the values recited above.

Expansion holes 113, as mentioned above are useful in that as expandedpolymer body 92 is molded, the polymer matrix expands through expansionholes 113 and the expanding polymer fuses. This allows the polymermatrix to encase and hold embedded studs 94 and 96 by way of the fusionin the expanding polymer. In an embodiment of the invention, expansionholes 113 can have a flanged and in many cases a rolled flange surfaceto provided added strength to the embedded metal studs.

In an embodiment of the invention, the floor system can be placed on afoundation. However, because foundations are rarely perfectly level, alevel track can be attached to the foundation prior to placement of thefloor system. The level track includes a top surface having a length andtwo side rails extending from opposing edges of the top surface, wherethe width of the top surface is greater than a width of the foundationand the length of the top surface is generally about the same as thelength of the foundation. The level track is generally attached to thefoundation by placing the level track over the foundation with the siderails generally contacting the sides of the foundation, situating thetop surface such that it conforms to level and permanently attaching thelevel track to the foundation. A rim joist can be used to aid inattaching the top surface to an end of the plurality of composite floorpanels.

More particularly, a level track 128 can be attached to foundation 130prior to placement of the floor system (see FIGS. 3 and 4). Level track128 can be placed on foundation 128 and leveled. The level is madepermanent by fastening level track 128 to foundation 130 by usingfasteners 131 (nails shown, although screws or other suitable devicescan be used) via fastening holes 132. Screws 133 can also be used toattach level track 128 to foundation 130 via screw holes 135. Some ofscrew holes 135 can be used in conjunction with screws 133 to attach abottom lip of joist rim 122 to level track 128. Screws 133 can alsomaintain the level position of level track 128 until a more permanentpositioning is achieved. Alternatively or additionally mortar can beapplied via mortar holes 134 to fill the space between level track 128and the top of foundation 130. After level track 128 has been attachedand/or the mortar has sufficiently set, the flooring system can befastened to the foundation.

Level track 128 includes side rails 137, which are adapted to extendover a portion of foundation 130. The width of level track 128 is thetransverse distance of a top portion of level track 128 from one siderail 137 to the other. The width of level track 128 is typicallyslightly larger than the width of foundation 130. The width of leveltrack 128 can be at least 10 cm, in some cases at least 15 cm, in othercases at least 20 cm and in some instances at least 21 cm. Also, thewidth of level track 128 can be up to 40 cm, in some cases up to 35 cm,and in other cases up to 30 cm. The width of level track 128 can be anyvalue or range between any of the values recited above.

The length of side rail 137 is the distance it extends from a topportion of level track 128 and is sufficient in length to allow forproper leveling of level track 128 and attachment to foundation 130 viafasteners 131 and fastening holes 132. The length of side rail 137 canbe at least 4 cm, in some cases at least 5 cm, and in other cases atleast 7 cm. Also, the length of side rail 137 can be up to 20 cm, insome cases up to 15 cm, and in other cases up to 12 cm. The length ofside rail 137 can be any value or range between any of the valuesrecited above.

An embodiment of the invention relates to a floor or tilt up insulatedpanel that is adapted to act as a concrete I-beam form. As shown in FIG.15, I-beam panel 140 includes expanded polymer form 142 (central body)and embedded metal members 144 and 146 (embedded reinforcing bars).Expanded polymer form 142 includes openings 148 that traverse all orpart of the length of expanded polymer form 142. The embedded metalmembers 144 and 146 have embedded ends 152 and 156 respectively that arein contact with inner face 150 of expanded polymer form 142. Theembedded metal members 144 and 146 also have exposed ends 158 and 160respectively that extend from outer face 162 of expanded polymer form142.

Expanded polymer form 142 can have a thickness, measured as the distancefrom inner face 150 to outer face 162 similar in dimensions to thatdescribed above regarding expanded polymer body 12.

Exposed ends 158 and 160 extend at least 1, in some cases at least 2,and in other cases at least 3 cm away outer face 162 of expanded polymerform 142. Also, Exposed ends 158 and 160 can extend up to 60, in somecases up to 40, and in other cases up to 20 cm away from outer face 162of expanded polymer form 142. Exposed ends 158 and 160 can extend any ofthe distances or can range between any of the distances recited abovefrom outer face 100.

In an embodiment of the invention, embedded metal members 144 and 146have a cross-sectional shape that includes embedding lengths 164 and166, embedded ends 152 and 156, and exposed ends 158 and 160. Theorientation of embedded metal members 144 and 146 is referenced by thedirection of open ends 168 and 170. In an embodiment of the invention,open ends 168 and 170 are oriented toward each other. In thisembodiment, I-beam panel 140 is adapted to be imbedded in concrete thatcan be applied to outer face 162.

The spacing between each of embedded metal members 144 and 146 can be asdescribed regarding embedded metal studs 14 and 16 in wall unit 10.

Openings 148 can have various cross-sectional shapes, and similarspacing and cross-sectional area as described regarding openings 18 inexpanded polymer body 12.

As shown in FIG. 15, expanded polymer panel 140 has a finite length andhas a male terminal end 170 that includes forward edge 172 and trailingedge 174 and a receiving end 176 which includes recessed section 178,which is adapted to receive forward edge 172, and protruding edge 180.Typically, lengths of I-beam panels 140 are interconnected by insertinga forward edge 172 from a first I-beam panel 140 into a recessed section178 of a second I-beam panel. In this manner, a larger roof, ceiling,floor or wall section containing any number of I-beam panels can beassembled and/or arrayed. The width of I-beam panel 140, measured as thedistance from protruding edge 180 to trailing edge 174 can typically beat least 20, in some cases at least 30, and in other cases at least 35cm and can be up to 150, in some cases up to 135, and in other cases upto 125 cm. The width of I-beam panel 140 can be any value or can rangebetween any of the values recited above.

I-beam panel 140 includes I-beam channel 182. The present I-beam panelis advantageous when compared to prior art systems in that theconnection between adjacent panels in the prior art is provided alongthe thin section of expanded polymer below I-beam channel 182. Theresulting thin edge is prone to damage and/or breakage during shipmentand handling. The I-beam panel of the present invention eliminates thisproblem by molding in the I-beam channel, eliminating the exposure of athin edge section to potential damage.

In an embodiment of the invention, rebar or other concrete reinforcingrods can be placed in I-beam channel 182 in order to strengthen andreinforce a concrete I-beam formed within I-beam channel 182.

In another embodiment of the invention shown in FIG. 16, instead ofI-beam channel 182, I-beam panel 141 includes channel 183. Channel 183is adapted to accept round ductwork or other mechanical and utilityparts and devices and/or can be filled with concrete as described above.

An example of an I-beam system 200 according to the invention is shownin FIG. 17, where four I-beam panels 140 are connected by inserting aforward edge 172 from a first I-beam panel 140 into a recessed section178 of a second I-beam panel. Concrete is poured, finished and set toform a concrete layer 202 that includes concrete I-beams 204, which areformed in I-beam channels 182. The embodiment shown in FIG. 17 is analternating embodiment, where the direction of I-beam channel 182 ofeach I-beam panel 140 alternately faces toward concrete layer 202 andincludes concrete I-beam 204 or faces away from concrete layer 202 andI-beam channel 182 does not contain concrete. In an embodiment of theinvention, the facing away I-beam panel can be I-beam panel 141.Alternatively, every I-beam panel 140 could face concrete layer 202 andinclude concrete I-beam 204.

In the embodiment shown, exposed ends 158 and 160 are either embedded inconcrete layer 202 or are exposed. The exposed ends 158 and 160 areavailable as attachment points for a finish surface 210, which caninclude wood, rigid plastics, wood paneling, concrete panels, cementpanels, drywall, sheetrock, particle board, rigid plastic panels, or anyother suitable material having decorating and/or structural functions orother construction substrates 210. The attachment is typicallyaccomplished through the use of screws, nails, adhesive or otherfasteners known in the art.

In an embodiment of the invention, I-beam system 200 is assembled on aflat surface and a first end is lifted while a second end remainsstationary resulting in orienting I-beam system 200 generallyperpendicular to the flat surface. This is often referred to as “tiltinga wall” in the art and in this embodiment of the invention, I-beamsystem 200 is referred to as a “tilt-wall.”

In another embodiment of the invention, I-beam system 200 can be used asa roof on a structure or a floor in a structure.

Embodiments of the present invention provide a composite building panelthat includes a central body, substantially parallelepipedic in shape,containing an expanded polymer matrix as described above, havingopposite faces, a top surface, and an opposing bottom surface; at leastone reinforcing embedded stud longitudinally extending across thecentral body between the opposite faces, having a first end embedded inthe expanded polymer matrix, a second end extending away from the bottomsurface of the central body, and one or more expansion holes located inthe embedded stud between the first end of the embedded stud and thebottom surface of the central body, where the central body contains apolymer matrix that expands through the expansion holes; and a concretelayer covers at least a portion of the top surface and/or bottomsurface.

A particular embodiment relates to a tilt up insulated panel that isadapted for use as a wall or ceiling panel. As shown in FIGS. 18-21,one-sided wall panel 340 includes a reinforced body 341 that includesexpanded polymer form 342 (central body) and embedded metal members 344and 346 (embedded reinforcing bars). Expanded polymer form 342 caninclude openings 348 that traverse all or part of the length of expandedpolymer form 342. The embedded metal members 344 and 346 have embeddedends 352 and 356 respectively that are not in contact with inner face350 of expanded polymer form 342. The embedded metal members 344 and 346also have exposed ends 358 and 360 respectively that extend from outerface 362 of expanded polymer form 342.

Expanded polymer form 342 can have a thickness, measured as the distancefrom inner face 350 to outer face 362 similar in dimensions to thatdescribed above regarding expanded polymer body 12.

Exposed ends 358 and 360 extend at least 1, in some cases at least 2,and in other cases at least 3 cm away outer face 362 of expanded polymerform 342. Also, Exposed ends 358 and 360 can extend up to 60, in somecases up to 40, and in other cases up to 20 cm away from outer face 362of expanded polymer form 342. Exposed ends 358 and 360 can extend any ofthe distances or can range between any of the distances recited abovefrom outer face 362.

In an embodiment of the invention, embedded metal members 344 and 346have a cross-sectional shape that includes embedding lengths 364 and366, embedded ends 352 and 356, and exposed ends 358 and 360. Theorientation of embedded metal members 344 and 346 is referenced by thedirection of embedded ends 352 and 356. In a particular embodiment ofthe invention, embedded ends 352 and 356 are oriented away from eachother. In this embodiment, one-sided wall panel 340 is adapted so thatexposed ends 358 and 360 of embedded metal members 344 and 346 areimbedded in concrete 370 that is applied to outer face 362.

The spacing between each of embedded metal members 344 and 346 can be asdescribed regarding embedded metal studs 14 and 16 in wall unit 10.

In an embodiment of the invention, one-sided wall panel 340 includesexpanded polymer body 342 (central body), embedded metal members 344 and346 (reinforcing embedded bars), which include flanges 311, corneredends 312, utility holes 346 located in an exposed portion of embeddedmetal members 344 and 346, expansion holes 313 in an embedded portion ofembedded metal members 344 and 346, and embedded ends 344 and 346, whichdo not touch inner face 350.

In an embodiment of the invention, inner face 350 can have a corrugatedsurface 351, which can be molded in or cut in, which enhances air flowbetween inner face 350 and any surface attached thereto.

Expansion holes 313 are useful in that as expanded polymer body 342 ismolded, the polymer matrix expands through expansion holes 313 and theexpanding polymer fuses. This allows the polymer matrix to encase andhold embedded metal members 344 and 346 by way of fusion in theexpanding polymer. In an embodiment of the invention, expansion holes313 can have a flanged and in many cases a rolled flange surface toprovided added strength to the embedded metal members.

Openings 348 can have various cross-sectional shapes, and similarspacing and cross-sectional area as described regarding openings 18 inexpanded polymer body 12.

Reinforced body 341 has a finite length and has a male terminal end 371that includes forward edge 372 and a receiving end 374, which includesrecessed section 376, which is adapted to receive forward edge 372.Typically, lengths of one-sided wall panel 340 are interconnected byinserting a forward edge 372 from a first one-sided wall panel 340 intoa recessed section 378 of a second one-sided wall panel. In this manner,a larger wall or ceiling section containing any number of one-sided wallpanels can be assembled and/or arrayed. The width of one-sided wallpanel 340, measured as the distance from protruding edge 380 to trailingedge 374 can typically be at least 20, in some cases at least 30, and inother cases at least 35 cm and can be up to 150, in some cases up to135, and in other cases up to 125 cm. The width of one-sided wall panel340 can be any value or can range between any of the values recitedabove.

Example of a one-sided wall panel 340 according to the invention isshown in FIGS. 20 and 21, where four embedded metal members 344 and 346are used. Concrete is poured, finished and set to form a concrete layer370 that encases exposed ends 358 and 360 of embedded metal members 344and 346.

The embedded ends 350 and 356 of embedded metal members 344 and 346 areavailable as attachment points for a finish surface 375 such as wood,rigid plastics, wood paneling, concrete panels, cement panels, drywall,sheetrock, particle board, rigid plastic panels, or any other suitablematerial having decorating and/or structural functions or otherconstruction substrates as shown in FIGS. 20 and 21). The attachment istypically accomplished through the use of screws, nails, adhesive orother fasteners known in the art.

In an embodiment of the invention, one-sided wall panel 340 is assembledon a flat surface and a first end is lifted while a second end remainsstationary resulting in orienting one-sided wall panel 340 generallyperpendicular to the flat surface. This is often referred to as “tiltinga wall” in the art and in this embodiment of the invention, one-sidedwall panel 340 is referred to as a “tilt-up wall.”

In embodiments of the tilt-up walls described herein, the exposed endsof the embedded metal members can act as a chair for the properplacement of reinforcing wire mesh and/or rebar or other reinforcingrods to the center of a concrete layer, poured, finished and set toencase the exposed ends.

In embodiments of the tilt-up walls described herein shown in FIG. 21,the exposed ends 358 and 360 of the embedded metal members 344 and 346can act as a chair for the proper placement of reinforcing wire mesh 371and/or rebar or other reinforcing rods to the center of a concrete layer370, poured, finished and set to encase the exposed ends

Another particular embodiment provides a composite building panel wherea first concrete layer covers at least a portion of the top surface andencases at least one first end of an embedded stud and a second concretelayer covers at least a portion of the bottom surface and encases atleast one second end of an embedded stud.

This particular embodiment of the invention can provide a second tilt upinsulated panel that is adapted for use as a wall or ceiling panel. Asshown in FIGS. 22-25, two-sided wall panel 440 includes a reinforcedbody 441 that includes expanded polymer form 442 (central body) andembedded metal members 444 and 446 (embedded reinforcing bars). Expandedpolymer form 442 can include openings 448 that traverse all or part ofthe length of expanded polymer form 442. The embedded metal members 444and 446 have a first exposed end 452 and second exposed end 456respectively that extend from first face 462 of expanded polymer form442. The embedded metal members 444 and 446 also have second exposedends 458 and 460 respectively that extend from second face 450 ofexpanded polymer form 442.

Expanded polymer form 442 can have a thickness, measured as the distancefrom second face 450 to first face 462 similar in dimensions to thatdescribed above regarding expanded polymer body 12.

The exposed ends can extend at least 1, in some cases at least 2, and inother cases at least 3 cm away either face 450 or face 462 of expandedpolymer form 442. Also, The exposed ends can extend up to 60, in somecases up to 40, and in other cases up to 20 cm away from either face ofexpanded polymer form 442. The exposed ends can extend any of thedistances or can range between any of the distances recited above fromeither face of expanded polymer form 442.

In an embodiment of the invention, exposed ends 452, 456, 458, and 460are imbedded in first concrete layer 469 and second concrete layer 470that are applied to faces 450 and 462.

The spacing between each of embedded metal members 444 and 446 can be asdescribed regarding embedded metal studs 14 and 16 in wall unit 10.

In an embodiment of the invention, two-sided wall panel 440 includesexpanded polymer body 442 (central body), embedded metal members 444 and446 (reinforcing embedded bars), with cornered ends 412, utility holes446 located in an exposed portion of embedded metal members 444 and 446,and expansion holes 413 in an embedded portion of embedded metal members444 and 446.

Expansion holes 413 are useful in that as expanded polymer body 442 ismolded, the polymer matrix expands through expansion holes 413 and theexpanding polymer fuses. This allows the polymer matrix to encase andhold embedded metal members 444 and 446 by way of fusion in theexpanding polymer. In an embodiment of the invention, expansion holes413 can have a flanged and in many cases a rolled flange surface toprovided added strength to the embedded metal members.

Openings 448 can have various cross-sectional shapes, and similarspacing and cross-sectional area as described regarding openings 18 inexpanded polymer body 12.

Reinforced body 441 has a finite length and has a male terminal end 471that includes forward edge 472 and a receiving end 476 which includesrecessed section 478, which is adapted to receive forward edge 472.Typically, lengths of two-sided wall panel 440 are interconnected byinserting a forward edge 472 from a first two-sided wall panel 440 intoa recessed section 478 of a second two-sided wall panel. In this manner,a larger wall, floor, roof or ceiling section containing any number oftwo-sided wall panels can be assembled and/or arrayed. The width ofone-sided wall panel 440, measured as the distance from forward edge 472to recessed section 478 can typically be at least 20, in some cases atleast 30, and in other cases at least 35 cm and can be up to 150, insome cases up to 135, and in other cases up to 125 cm. The width oftwo-sided wall panel 440 can be any value or can range between any ofthe values recited above.

An example of a two-sided wall panel 440 according to the invention isshown in FIG. 24, where four embedded metal members 444 and 446 areused. Concrete is poured, finished and set to form concrete layers 469and 470 that encases exposed ends 452, 456, 458, and 460 of the embeddedmetal members.

Alternatively, as shown in FIG. 25, one or both of exposed ends 452 and456 and/or 458 and 460 are available as attachment points for a finishsurface 475 such as wood, rigid plastics, wood paneling, concretepanels, cement panels, drywall, sheetrock, particle board, rigid plasticpanels, or any other suitable material having decorating and/orstructural functions or other construction substrates. The attachment istypically accomplished through the use of screws, nails, adhesives orother fasteners known in the art. In this embodiment, the space 476defined by the finished surface 475, exposed ends 452 and 456 and theexpanded polymer body 442 can be used to run utilities, insulation andanchors for interior finishes as described above.

The present invention provides a method of constructing a building thatincludes assembling any of the above-described composite building panelson a generally flat surface, and lifting a first end of the compositebuilding panel while a second end remains stationary resulting inorienting the building panel to form a wall of the building.

In an embodiment of the invention, two-sided wall panel 440 is assembledon a flat surface and a first end is lifted while a second end remainsstationary resulting in orienting two-sided wall panel 440 generallyperpendicular to the flat surface. This is often referred to as “tiltinga wall” in the art and in this embodiment of the invention, two-sidedwall panel 440 is referred to as a “tilt-up wall.”

In embodiments of the tilt-up walls described herein and shown in FIG.25, the exposed ends 458 and 460 of the embedded metal members 444 and446 can act as a chair for the proper placement of reinforcing wire mesh471 and/or rebar or other reinforcing rods to the center of a concretelayer 470, poured, finished and set to encase the exposed ends.

In an embodiment of the invention, when the exposed ends of theone-sided wall panel and the two sided wall panel are encased inconcrete as described above, utility holes 346 and 446 act as siteswhere the set and hardened concrete fuses through the holes and therebyholds and attaches to the embedded metal members. Additionally,reinforcing rods can be placed through utility holes 346 and 446connecting embedded metal members, thus further strengthening the formedwall panel.

As used herein, the term “concrete” refers to a hard strong buildingmaterial made by mixing a cementitous mixture with sufficient water tocause the cementitous mixture to set and bind the entire mass as isknown in the art.

In an embodiment of the invention, the concrete can be a so called“light weight concrete” in which light weight aggregate is included withthe cementitous mixture. Exemplary light weight concrete compositionsthat can be used in the present invention are disclosed in U.S. Pat.Nos. 3,021,291, 3,214,393, 3,257,338, 3,272,765, 5,622,556, 5,725,652,5,580,378, and 6,851,235, JP 9 071 449, WO 98 02 397, WO 00/61519, andWO 01/66485 the relevant portions of which are incorporated herein byreference.

The wall units, floor units, tilt up insulated panels and I-beam panelsdescribed herein contain variations that are not meant as limitations.Any of the variations discussed in one embodiment can be used in anotherembodiment without limitation.

The embodiment of the invention shown in FIG. 14 shows an example ofusing combinations of the composite panels described herein andcombining features of the various panels. This embodiment combinesI-beam panel 140 and floor panel 92 (shown as 92 and 92A). In thisembodiment, receiving end 176 of I-beam panel 140 accepts forward edge93 of floor panel 92 and recessed section 99 of floor panel 92A acceptsforward edge 172 of I-beam panel 140 to provide tongue and grooveconnections to establish continuous floor system 141. In thisembodiment, circular ductwork 148 is installed along bottom surface 100of floor panel 92 between embedded metal joists 94 and 96. In thisembodiment, the flooring material is concrete layer 145, which coverstop surface 102 of floor panels 92 and 92A and outer face 162 of I-beampanel 140. I-beam channel 182 extends from and is open to outer face 162and is filled with concrete and the thickness of concrete layer 145 issufficient to encase exposed ends 158 and 160 of I-beam panel 140. Thecombination shown in this embodiment provides an insulated concretefloor system where utilities can be run under an insulation layer.

In an embodiment of the invention, a lath can be attached to the exposedends of the metal studs, metal joists or metal members of the wallunits, floor units, and expanded polymer panels; i.e. constructionelements, of the invention. The lath is capable of supporting a coveringlayer constituted by a suitable construction material. The lath caninclude one or more portions extending flush on opposite lateral sidesof the construction element, which can be embedded in and anchored alsoto the concrete used for incorporating and/or joining together one ormore adjacent construction elements.

The lath can support one or more covering layers and is typically astretched metallic lath including a rhomb-shaped mesh having alength-to-height rhomb ratio of about 2:1. The rhomb length can varybetween 20 and 60 mm, while the rhomb width can vary between 10 and 30mm. The stretched metallic lath can have a thickness of from 0.4 to 1.5mm and, in some cases of from 0.4 to 1.0 mm.

The covering layers can include one or more coating layers of plaster,stucco, cement as it is or, optionally, reinforced with fibers of asuitable material.

In an embodiment of the invention shown in FIG. 29, outer surface 24 ofexpanded polymer body 12 can have any desirable type of surface. In someinstances, outer surface 24 will be smooth, in other instances groovescan be cut or molded into outer surface 24, in other cases outer surface24 can have ridges along the surface to facilitate air flow, and inparticular cases, as shown in FIG. 29, outer surface 24 can be adaptedto accept stucco. In order to facilitate the application of stucco toouter surface 24, T-slots 1300 can be cut into or molded into outersurface 24. Any suitable type of stucco can be used, non-limitingexamples including natural material stucco or polymer based stucco.Thus, by including T-slots 1300 in outer surface 24, a stucco-readypanel surface is provided. More particularly, T-slots 1300 provide amechanical connection for stucco adhesion and no secondary mesh isrequired. In a particular embodiment of the invention, T-slots 1300allow for the use of natural material stucco, as this type of stucco isable to breathe and not trap moisture. When stucco is not applied toouter surface 24, T-slots 1300 can be used as water condensationchannels or for other finishing techniques.

A particular advantage of the construction panels, wall units, floorunits, and expanded polymer panels according to the invention isdirected to fire protection and safety. As described above, a portion ofthe embedded framing studs or embedded floor joists are exposed and caninclude a web of holes formed along their length. By exposing a sectionof the web of holes in the embedded framing studs or embedded floorjoists, air flow is encouraged and in a fire situation, cooling of theweb section of the embedded framing studs or embedded floor joists takesplace. This can be very important to prolonging the failure time of aloaded wall section. Typically, in a fire test, an insulated metal studwill fail before a non-insulated stud in the center web area.

Locating spanner bars, as described above, in the exposed web section,the embedded framing studs or embedded floor joists act as a heat sink,helping to dissipate heat from the center web section of the embeddedframing studs or embedded floor joists as well as adding to thestructural properties of the wall.

The melting properties of the polymer matrix in a fire situation furtherfacilitates the cooling of the embedded framing studs or embedded floorjoists web section by melting away from the web as the temperatureexceeds 200° F., allowing further air circulation and cooling of theweb.

The bottom track of the wall panel, as described above, can be designedto act as a drip and containment pan in a fire event. The bottom trackarea is designed to contain the solids that melt when the polymer matrixburns. The bottom track is adapted to hold a volume at least equivalentto the volume of the expanded polymer matrix in the expanded polymerbody in liquid or molten form. Each track section can be designed tohave a holding capacity of from at least 0.2 ft³, in some instances atleast 0.25 ft³, in some cases at least 0.3 ft³ and in other cases atleast 0.4 ft³ and the holding capacity can be up to 0.75 ft³, in somecases up to 0.65 ft³ and in other cases up to 0.1 ft³ of liquid ormolten material. The containment volume in the bottom track can be anyvalue or range between any of the values recited above. The holdingcapacity of the bottom track is typically designed to contain the solidscontained in a typical 48″×96″ construction panel.

In lager construction panels, for example those of greater height, theexterior portion of the bottom track can be slotted, allowing for theevacuation of melt materials to the exterior of the building. Thisdesign greatly diminishes the interior fire spread and improves thesafety of the interior environment of the structure during initial firespread and rescue operations.

Embodiments of the present invention provide a stay in place insulatingconcrete forming system that is continuous in nature with length beinglimited only by transportation and handling limitations. The presentinsulating concrete forming system includes two opposing foamed plasticfaces connected internally and spaced apart by perforated structuralmetal members. The foamed plastic faces and metal spacing members arealigned within the form to properly position vertically and horizontallyconcrete reinforcement steel, while allowing for proper concrete flowand finish work attachments. The molded in structural steel members actas internal bracing keeping the forms straight and aligned duringconcrete placement eliminating the need for most external blocking.

Further, the present invention provides pre-formed insulated concreteforms that include one or more reinforcing structural elements or barsrunning longitudinally, the end of which are at least partially embeddedin oppositely facing expanded polymer bodies. The remainder of thereinforcing structural element(s), the portion between the expandedpolymer bodies, are at least partially exposed. The portions of the endsthat are encapsulated in the expanded polymer matrix can provide athermal break from the external environment. The reinforcing structuralelements can be flanged lengthwise on either side to provide attachmentpoints for external objects to the panel. Perforations in thereinforcing structural elements in the end portions which areencapsulated in the expanded polymer matrix allow for fusion of theexpandable polymer particles perpendicularly. Perforations in theexposed portion of the reinforcing structural element provide attachmentpoints for lateral bracing and/or rebar and allow for uniform concreteflow when concrete is poured into the present insulated concrete form. Atongue and groove or overlapping connection point design provides forpanel abutment while maintaining the integrity of the concrete form.Longitudinal holes can run through the expanded polymer matrix and canbe variable in diameter and location to provide areas for placement ofutilities, lightening the structure and channels for venting of gasses.Panel manufacture is accomplished through the use of a semi-continuousor continuous molding process allowing for variable panel lengths.

The embedded studs used in the invention can be made of any suitablematerial as described above. In a particular embodiment of theinvention, the embedded studs are made of a light gauge metal.

The embedded studs can have a thickness as described above. Thethickness of the embedded studs will depend on the intended use of thepre-formed building panel.

In an embodiment of the invention, the embedded studs have holes oropenings along their length to facilitate fusion of the expanded plasticmaterial and to reduce any thermal bridging effects in the reinforcingbars, studs, joists and/or members.

In the present invention, the foamed plastic faces can be molded fromany suitable expandable plastic material, as described above, on amolding machine capable of inserting the metal members and forming twoopposing face panels while maintaining the composite materials in theirrelative position in a continuous or semi continuous process.

In a particular embodiment of the invention, the expandablethermoplastic particles are expandable polystyrene (EPS) particles.These particles can be in the form of beads, granules, or otherparticles convenient for the expansion and molding operations asdescribed above.

More particularly, the present insulated concrete form includes a firstbody, substantially parallelepipedic in shape, containing an expandedpolymer matrix, having opposite faces, a first surface, and an opposingsecond surface; a second body, substantially parallelepipedic in shape,containing an expanded polymer matrix, having opposite faces, a firstsurface, an opposing second surface; and one or more embedded studslongitudinally extending across the first body and the second bodybetween the first surfaces of each body, having a first end embedded inthe expanded polymer matrix of the first body, and a second end embeddedin the expanded polymer matrix of the second body. One or more expansionholes are provided in the portion of the embedded stud embedded in thefirst body and the second body. The first body and the second bodyinclude a polymer matrix that expands through the expansion holes. Thespace defined between the first surfaces of the first body and thesecond body is capable of accepting concrete poured therein.

An embodiment of the present invention provides insulated concrete forms(ICF) and ICF systems. As shown in FIG. 30, ICF 510 includes firstexpanded polymer body 511 and second expanded polymer body 512, leftfacing embedded metal studs 514, and right facing embedded metal studs516 (reinforcing embed bars). The embedded metal studs 514 and 516 haveembedded ends 520 and 522 respectively that do not touch outer surface524 of first expanded polymer body 511. Embedded metal studs 514 and 516have embedded ends 521 and 523 respectively that are adjacent to outersurface 525 of second expanded polymer body 512. Space 505 is defined asthe space between inner surface 530 of first expanded polymer body 511and inner surface 531 of second expanded polymer body 512 for the heightof ICF 510.

Expanded polymer bodies 511 and 512 can have a thickness, measured asthe distance from inner surface 530 or 531 respectively to outer surface524 or 525 respectively of at least 2, in some cases at least 2.5, andin other cases at least 3 cm and can be up to 10, in some cases up to 8,and in other cases up to 6 cm from inner surface 30 of expanded polymerbody 512. The thickness of expanded polymer bodies 511 and 512 canindependently be any dimension or range between any of the dimensionsrecited above.

Embedded ends 520 and 522 extend at least 1, in some cases at least 2,and in other cases at least 3 cm into expanded polymer body 512 awayfrom inner surface 530. Also, Embedded ends 520 and 522 can extend up to10, in some cases up to 8, and in other cases up to 6 cm away from innersurface 530 into first expanded polymer body 511. Embedded ends 526 and528 can extend any of the distances or can range between any of thedistances recited above from inner surface 530 into polymer body 511.

In another embodiment of the invention, embedded ends 520 and 522 canextend from 1/10 to 9/10, in some cases ⅓ to ⅔ and in other cases ¼ to ¾of the thickness of first expanded polymer body 511 into expandedpolymer body 511.

The orientation of embedded metal studs 514 and 516 is referenced by thedirection of ends 520, 521, 522, and 523. The ends can be oriented inany direction that suits the strength, attachment objectives orstability of the insulated concrete form.

The spacing between each of embedded metal studs 514 and 516 istypically adapted to be consistent with local construction codes ormethods, but can be modified to suit special needs. As such, the spacingbetween the metal studs can be at least 10, in some instances at least25 and in some cases at least 30 cm and can be up to 110, in some casesup to 100, in other cases up to 75, and in some instances up to 60 cm.The spacing between embedded metal studs 514 and 516 can be any distanceor range between any of the distances recited above.

ICF 510 can extend for a distance with alternating embedded metal studs514 and 516 placed therein. The length of ICF 510 can be any length thatallows for safe handling and minimal damage to ICF 510. The length ofICF 510 can typically be at least 1, in some cases at least 1.5, and inother cases at least 2 m and can be up to 25, in some cases up to 20, inother cases up to 15, in some instances up to 10 and in other instancesup to 5 m. The length of ICF 510 can be any value or can range betweenany of the values recited above. In some embodiments of the invention,each end of ICF 510 is terminated with an embedded metal stud.

The height of ICF 510 can be any height that allows for safe handling,minimal damage, and can withstand the pressure from concrete pouredwithin ICF 510. The height of ICF 510 can be at least 1 and in somecases at least 1.25 m and can be up to 3 M and in some cases up to 2.5m. In some instances, in order to add stability to ICF unit 510,reinforcing cross-members or rebar (not shown) can be attached toembedded metal studs 514 and 516. The height of ICF 10 can be any valueor can range between any of the values recited above.

Space 505, the space between inner surface 530 and inner surface 531 forthe height of ICF 510, can be any suitable volume and/or dimensions.Suitable volume and/or dimensions are those where the weight of concretepoured into space 505 is no so high as to cause any part of ICF 510 tofail, i.e., allow concrete to break through ICF 510 such that the volumeof concrete is not contained in space 505, but large enough that thepoured and set concrete can support whatever is to be built on theresulting ICF concrete wall. Thus, the distance between inner surface530 and inner surface 531 taken with the height defined above can be atleast 5 in some cases at least 10 and in other cases at least 12 cm andcan be up to 180, in some cases up to 150 cm and in other cases up to120 cm. In some instances, in order to add stability to ICF unit 510,reinforcing cross-members or rebar (not shown) can be attached toembedded metal studs 514 and 516. The distance between inner surface 530and inner surface 531 can be any value or can range between any of thevalues recited above.

In a particular embodiment of the invention, ICF 510 can be used as astorm wall. In this embodiment, space 505 is filled with concrete asdescribed herein and the distance from inner surface 530 to innersurface 531 can be at least 2 in some cases at least 5 and in othercases at least 10 cm and can be up to 16, in some cases up to 14 cm andin other cases up to 12 cm. In this storm wall embodiment, the distancebetween inner surface 530 and inner surface 531 can be any value or canrange between any of the values recited above.

Storm walls made according to the present invention can be used as anyof the other wall panels and tilt-up walls described herein.

As shown in FIG. 30, ICF 510 has a finite length and first body 511 andsecond body 512 have an inner lip terminus 517 and an outer lip terminus518. Typically, lengths of ICF 510 are interconnected by inserting aninner lip terminus 517 of one ICF 510 adjacent an outer lip terminus 518of another ICF 510 to form a continuous ICF. Thus, a larger ICFcontaining any number of ICF 510 units can be assembled and/or arrayed.

An alternative embodiment of the invention is shown in FIG. 31, whereICF 508 is similar to ICF 510 except that inner surface 530 of body 511and inner surface 531 of body 512 include oppositely opposed innerarching sections 532 and 534 respectively. Inner arching sections 532and 534 provide a non-linear space within ICF 508, such that concretepoured into ICF 508 will have sections that have a largercross-sectional width and sections having a smaller cross-sectionalwidth.

In another embodiment of the invention shown in FIG. 32, ICF 509 hasexposed ends 536 and 538 instead of embedded ends 521 and 523. Exposedends 536 and 538 extend at least 1, in some cases at least 2, and inother cases at least 3 cm away from outer surface 525 of second expandedpolymer body 512. Exposed ends 536 and 538 can be used to attach finishsurfaces, such as drywall, plywood, paneling, etc. as described above toICF 509. Also, Exposed ends 536 and 538 can extend up to 60, in somecases up to 40, and in other cases up to 20 cm away from outer surface525 of expanded polymer body 512. Exposed ends 536 and 538 can extendany of the distances or can range between any of the distances recitedabove from outer surface 525.

Referring to FIG. 32, embedded metal studs 514 and 516 can have utilityholes spaced along their length between outer surface 525 and exposedends 536 and 538. The utility holes (not shown here, but as describedand illustrated above) are useful for accommodating utilities such aswiring for electricity, telephone, cable television, speakers, and otherelectronic devices, gas lines and water lines. The utility holes canhave various cross-sectional shapes, non-limiting examples being round,oval, elliptical, square, rectangular, triangular, hexagonal oroctagonal. The cross-sectional area of the utility holes can also varyindependently one from another or they can be uniform. Thecross-sectional area of the utility holes is limited by the dimensionsof embedded metal studs 514 and 516, as the utility holes will fitwithin their dimensions and not significantly detract from theirstructural integrity and strength. The cross-sectional area of theutility holes can independently be at least 1, in some cases at least 2,and in other cases at least 5 cm² and can be up to 30, in some cases upto 25, in other cases up to 20 cm². The cross-sectional area of theutility holes can independently be any value or range between any of thevalues recited above.

In an embodiment of the invention, the utility holes can have a flangedand in many cases a rolled flange surface to provided added strength tothe embedded metal studs.

FIGS. 33 and 34 show features of the present ICF as they relate to ICF508 (FIG. 31). A feature of embedded metal studs 514 and 516 is thatthey can include expansion holes 540 and pour holes 542. As such pourholes 544 can be a punched hole extending along the vertical axis ofembedded metal studs 514 and/or 516 that is positioned to allow the freeflow of normal concrete and to fix and position horizontal concretereinforcements. Similarly, expansion holes 540 can be a punched hole ofsufficient diameter or slot of sufficient void area to allow the fusionand flow of the polymer matrix through the formed plastic panel.

The molded in light gauge metal structural members, embedded metal studs514 and 516, can be continuously or semi continuously formed to create acomposite panel of unlimited length. The structural metal members arestrategically punched along the outer vertical axis to provide expansionholes 540, which allow for the flow of and fusion of the expandableplastic materials through the metal members. The center vertical axis ofthe metal member is punched to provide pour holes 542, which permit thefree flow of normal concrete and to aid in the fixing and placement ofhorizontal concrete reinforcement materials. FIGS. 35 and 36 shows theformed and set concrete 550 in relation to embedded metal studs 514 and516.

Embedded ends 521 and 523 act as continuous furring strips runningvertically on predetermined centers to aid in the direct connection offinish materials, top and bottom structural tracks, wall penetrationsand roof and floor connection points, such as the level track describedherein.

The expandable plastic materials in the composite panel acts as aforming panel when concrete is placed within the form also providesinsulation and sound deadening. Further, the expandable plasticmaterials face of the composite panel acts as a forming panel whenconcrete is placed within the form and also provides insulation andsound deadening.

The design of the present ICF provides horizontal and vertical concretepathways created by the two opposing face panels fixed by the lightgauge structural members.

When concrete is poured into space 505 of the present ICF, an internalconcrete post is formed by the two opposing face panels within thevertical post wall configuration of the panel design. The concrete corecreated in the form acts as horizontal bracing to the light-gaugestructural metal members in the present ICF. In the vertical post wallpanel design the concrete core allows for horizontal reinforcement alongthe axis of the vertical post created between the form face panels.

In the present ICF, the interlocking panel ends formed by inner lip 517and outer lip 518 are self aligning, self sealing and securely connectone panel side termination to the other panel side termination point,forming a continuous horizontal as well as continuous vertical concreteplacement form.

FIG. 37 shows an embodiment of the invention where the surface of steelmember 560, which can be used as embedded metal studs 514 and/or 516 inthe present ICF are dimpled 565 in opposing directions creating asurface that increases concrete adhesion and prevents cracking of theconcrete in contact with steel member 560. The dimple effect on themember surface adds to the shear resistance of the steel and concretecomposition. The dimpling of the steel surface creates a strongerconnection between the foam and the steel member of the plastic foamfaces of the panel when molded as a composite structure.

FIG. 38 shows an insulated concrete form system 575 for providing afoundation that includes a plurality of ICF's 508 connected end to endto form ICF system 575. Corner unit 552 is used to interconnect parallelICF lines 554 and perpendicular ICF lines 556. Concrete is poured intospace 505 of ICF wall system 575 and cured to form a completed insulatedconcrete wall system.

Corner unit 552, as shown in FIG. 39 essentially includes a first ICF508A and a second ICF 508B (like features are numbered as above)oriented at an angle to first ICF 508A, where corner section 562 ismolded to include first ICF 508A and second ICF 508B to form acontinuous first body and second body and providing a continuous space505 there between.

Referring to FIG. 32, a particular advantages of ICF 509 includes theability to easily run utilities prior to attaching a finish surface tothe exposed ends of the embedded metal studs. The exposed metal studsfacilitate field structural framing changes and additions and leave thestructural portions of the assembly exposed for local building officialsto inspect the framing.

A utility space defined by outer surface 525 of expanded polymer body512 and exposed ends 536 and 538 can be adapted for accommodatingutilities. Typically, exposed ends 536 and 538 have a finish surfaceattached to them, a side of which further defines the utility space.

In an embodiment of the invention, the utility space is adapted anddimensioned to receive standard and/or pre-manufactured components, suchas windows, doors and medicine cabinets as well as customized cabinetsand shelving.

Further, the air space between the outer surface of the expanded polymerbody 512 and the finish surface allows for improved air circulation,which can minimize or prevent mildew. Additionally, because the metalstuds are not in direct contact with the outside environment, thermalbridging via the highly conductive embedded metal studs is avoided andinsulation properties are improved.

The various embodiments described herein contain variations that are notmeant as limitations. Any of the relevant variations discussed in theembodiments of ICF, building, floor, ceiling, wall, and/or roof panelscan be used in the ICF, building, floor, ceiling, wall, and/or roofpanel embodiments described herein without limitation.

In an embodiment of the invention, a lath can be attached to the exposedends of the metal studs, metal joists or metal members of the ICF of theinvention. The lath is capable of supporting a covering layerconstituted by a suitable construction material. The lath can includeone or more portions extending flush on opposite lateral sides of theconstruction element, which can be embedded in and anchored also to theconcrete used for incorporating and/or joining together one or moreadjacent construction elements.

The lath can support one or more covering layers and is typically astretched metallic lath including a rhomb-shaped mesh having alength-to-height rhomb ratio of about 2:1. The rhomb length can varybetween 20 and 60 mm, while the rhomb width can vary between 10 and 30mm. The stretched metallic lath can have a thickness of from 0.4 to 1.5mm and, in some cases of from 0.4 to 1.0 mm.

The covering layers can include one or more coating layers of plaster,stucco, cement as it is or, optionally, reinforced with fibers of asuitable material.

In an embodiment of the invention, referring to FIGS. 3 and 38,insulated concrete form system 575 is foundation 130, where level track128 is attached thereto as described above. Further, the inventionprovides buildings that include the present insulated concrete formsystem as a foundation, with an optional level track according to theinvention attached thereto, and one or more floor panels, floor systems,wall panels, wall systems, tilt-up walls, storm panels, ceiling and/orroof panels as described herein. In a particular embodiment of theinvention, the floor panels, floor systems, wall panels, wall systems,tilt-up walls and/or storm panels can be attached to the insulatedconcrete form system, optionally using the present level track. Furtherto this particular embodiment, the present ceiling and/or roof panelscan be attached to one or more of the present wall panels, wall systems,tilt-up walls and/or storm panels. Thus a novel building is provided.

The ICF units of the present invention can be made using an apparatusfor molding a semi-continuous or continuous foamed plastic element thatincludes

a first mold including:

i) a bottom wall, a pair of opposite side walls and a cover, and

ii) a molding seat, having a shape mating that of the element, definedin the mold between the side walls, the bottom wall and the cover;

a second mold including:

i) a bottom wall, a pair of opposite side walls and a cover, and

ii) a molding seat, having a shape mating that of the element, definedin the mold between the side walls, the bottom wall and the cover;

b) means for displacing the covers and the side walls of the moldstowards and away from the bottom wall to longitudinally close andrespectively open the mold; and

c) first means for positioning in an adjustable manner said covers awayfrom and towards said bottom wall of the mold to control in anadjustable and substantially continuous manner the height of the moldingseat.

The apparatus is configured to include the reinforcing members, embeddedmetal bars, embedded metal studs, embedded metal joists, and embeddedmetal members configured as discussed above. As a non-limiting example,the methods and apparatus disclosed in U.S. Pat. No. 5,792,481 can beadapted to make the ICF units, of the present invention. The relevantparts of U.S. Pat. No. 5,792,481 are incorporated herein by reference.

The wall units, floor units, and expanded polymer panels of the presentinvention can be made using batch shape molding techniques. However,this approach can lead to inconsistencies and can be very time intensiveand expensive.

In an embodiment of the invention, the wall units, ceiling units, roofunits, floor units, and expanded polymer panels of the present inventioncan be made using an apparatus for molding a semi-continuous orcontinuous foamed plastic element that includes

a) a mold including:

-   -   i) a bottom wall, a pair of opposite side walls and a cover, and    -   ii) a molding seat, having a shape mating that of the element,        defined in the mold between the side walls, the bottom wall and        the cover;

b) means for displacing the cover and the side walls of the mold towardsand away from the bottom wall to longitudinally close and respectivelyopen the mold; and

c) first means for positioning in an adjustable manner said cover awayfrom and towards said bottom wall of the mold to control in anadjustable and substantially continuous manner the height of the moldingseat.

The apparatus is configured to include the reinforcing members, embeddedmetal bars, embedded metal studs, embedded metal joists, and embeddedmetal members configured as discussed above. As a non-limiting example,the methods and apparatus disclosed in U.S. Pat. No. 5,792,481 can beadapted to make the wall units, floor units, and expanded polymer panelsof the present invention. The relevant parts of U.S. Pat. No. 5,792,481are incorporated herein by reference.

In an embodiment of the invention, the reinforcing members, embeddedmetal studs, embedded metal joists, and/or embedded metal members 220can be molded into the wall units, floor units, and expanded polymerpanels having a formed embedded end 222 and a straight exposed end 224as shown in FIG. 26. Subsequently, the straight exposed end can beformed, worked and/or modified to provide a shaped end 228A as shown inshaped member 226A in FIG. 27 or a shaped end 228B as shown in shapedmember 226B FIG. 28. Embedded ends 226A and 226B can remain unchangedfrom embedded end 222. Equipment and machinery for subsequently bending,working, forming or modifying the exposed end are well known in the art.

In an embodiment of the invention, the inner surface, bottom surface, orinner face of the wall units, floor units, and expanded polymer panelsdescribed above can have a grooved surface, either molded in or appliedmechanically to improve air flow through the annular space between theexpanded plastic and any materials attached to the exposed ends of themetal studs, metal joists or metal members of the wall units, floorunits and expanded polymer panels described above.

The present invention is directed to a method of constructing a buildingin a first embodiment including:

providing a foundation having a series of walls having top surfaces,which can include the present insulated concrete form system;

positioning and securing the composite building panels described above,adapted for use as a floor unit, and/or floor panels or floor systems asdescribed herein, such that the floor unit, panel and/or system spans atleast a portion of the top surfaces of the foundation walls;

positioning and securing any of the wall systems described above to thefloor unit or system; and

positioning and securing a roof system as described above to a topsurface of the wall system.

Another embodiment of the invention provides a method of constructing abuilding that includes:

providing a foundation having a series of foundation walls having topsurfaces, which can include the present insulated concrete form system;

positioning and securing the composite building panels described above,adapted for use as a floor unit, and/or floor panels or floor systems asdescribed herein, such that the floor unit, panel and/or system spans atleast a portion of the top surfaces of the foundation walls;

positioning and securing two or more of the composite building panelsand/or storm panels described above, adapted for use as a wall unit, toat least part of a top surface of the floor unit, wherein a bottom trackand a top slip track are attached to a bottom end and a top endrespectively of the composite building panels; and

positioning and securing the composite building panels described above,adapted for use as a roof unit, to at least some of the top slip trackof the wall units.

Further to this embodiment, a method of constructing a multi-storybuilding is provides that further includes:

positioning and securing the composite building panels described above,adapted for use as a second floor unit or system, to at least a portionof the top slip track of the wall units; and

positioning and securing two or more of the composite building panelsand/or storm panels described above, adapted for use as a second wallunit, to at least part of a top surface of the second floor unit,wherein a bottom track and a top slip track are attached to a bottom endand a top end respectively of the composite building panels;

where the roof unit is secured to at least some of the top slip track ofthe second wall units.

Thus, the present invention also provides a building that contains oneor more of the floor units, wall systems and roof systems describedabove.

The wall units, floor units and expanded polymer panels of the presentinvention provide a number of advantages. For example, they typicallyeliminate the need for house wrap. The expanded polymers used in thepresent invention typically have at least an equivalent rating asrequired by local building codes for house wraps.

Also, no insulation subcontractors are required during construction asthe wall units, floor units and expanded polymer panels of the inventionalready include adequate insulation. The materials of construction alsoeffectively blocks low frequency sound waves resulting from exteriornoise.

The acoustical properties of the construction panels, wall units, floorunits and expanded polymer panels according to the invention areparticularly advantageous. Typically, metal studded structures havemajor acoustical or sound transmission problems. The metal studs willgenerally amplify sound through their ability to vibrate. When the metalstuds are encapsulated in the polymer matrix, vibration is reduced,which results in reduced vibration and desirable acoustical and soundtransmission properties.

Further, less framing is required on a job site because of theprefabricated nature of the present wall units, floor units and expandedpolymer panels.

The generally faster construction time resulting from using the presentwall units, floor units and expanded polymer panels allows for earlierenclosure and protection from the elements leading to less water damageduring construction. Additionally, the provided holes, openings,conduits, chases and spaces in the present wall units, floor units andexpanded polymer panels results in faster wiring and plumbing and lessjob site scrap.

The present invention also relates to a method of doing business thatallows an architectural design layout to be accessed by the apparatusfor molding a semi-continuous or continuous foamed plastic element inorder to customize the size, shape and dimensions of the variouselements of the construction panels, wall units, floor units, andexpanded polymer panels of the invention. The architectural designlayout can be provided via software from a disk or via an Internetconnection. For those customers with Internet capabilities, access tothe present method is convenient and provides an efficient and timesaving method to design and manufacture building and/or housing units.

In a non-limiting exemplary embodiment, a customer selects anarchitectural design for a building. The architectural design includesthe unique features of each composite building panel to be used in thebuilding. The architectural design is loaded into a processing unit thattranslates the design into instructions for the apparatus for molding asemi-continuous or continuous foamed plastic element. The instructionsdirect the apparatus to continuously or semi-continuously mold panels asdescribed above and what customizing features to include in each panel.

The architectural design can include, as non-limiting examples thedimensions of and the location of openings and holes required in eachreinforcing embedded stud as well as any indentations in each compositebuilding panel needed to build the building; the dimensions of eachcomposite building panel to include thickness, width, height, spacingbetween embedded studs, dimensions and shape for each embedded stud, anychannels that need to be cut into or formed in the central body of eachcomposite building panel, any of the design features described above,any other unique features for each composite building panel, as well asgable ends accommodating any roof pitch or slope, bay window floor cutsand other design specified architectural features.

The processing unit can be any computer or device capable of readinginstructions and translating them into instructions for the apparatusfor molding a semi-continuous or continuous foamed plastic element.

The customizing features can include any of the architectural designfeatures described above. As a non-limiting example, the customizingfeatures can include forming a straight exposed end as shown in FIG. 26to a shaped end as shown in either of FIGS. 27 and 28.

In another embodiment of the invention, an interactive computer programcan be used to provide the architectural designs described above. In anembodiment of the invention, the architectural design can be inputtedusing a series of computer screen menus, where a user selects choicesmade available on a computer screen. When the design button is selected,a screen appears for additional choices for modifying the central body,the embedded framing studs or embedded floor joists, and/or the spatialrelationship between the two. Selecting any of the menus directs toanother screen where specific architectural design features as describedabove can be inputted as well as the number of panels required that havethose features. Upon selection, additional customized panels can beinputted. The user then verifies the order by selecting an “orderpanels” button. The instructions are then relayed to the apparatus formolding a semi-continuous or continuous foamed plastic element and eachof the requested number of panels having each of the architecturaldesign features are molded and cut to the order specifications. In anembodiment of the invention, all panels are automatically labeled andmarked for placement in their proper position.

In a further embodiment, the customer requests access to an interactiveprogram that steps the customer through the design process. Once thedesign is complete, the customer can save the design for future use. Thecustomer may also choose to submit the design for an order.

The use of a design program on an Internet site benefits themanufacturer in a variety of ways including a method of gatheringcustomer profiles that can later be used for mailings, etc. In addition,an Internet site that includes this unique method of doing businessreaches worldwide and generates name recognition for the manufacturer,particularly where the construction panel manufacturer is the is theonly manufacturer to offer an accessible and convenient method ofdesigning and ordering composite construction panels.

The design program of the invention provides an advantage for the userin his or her own business in that it raises the level ofprofessionalism of the user by allowing prompt and on-the-spot servicefor his or her own customers. For example, a customer may bring a sketchor layout for an architectural design a composite construction panelshop requesting construction panels to use in the layout or design. Inresponse, the panel shop owner, i.e., user, can utilize the designprogram to build a series of composite construction panels on a computerscreen with the customer by his side, and explain to the customer thebenefits of the custom composite construction panels. This processprovides a first rate service to the customer, eliminates guessing,increases interaction between the panel shop and the end customer, andenhances business reputation in the field.

FIG. 40 illustrates a method of doing business 400 between a compositeconstruction panel manufacturer 420 and a customer 414, 416 requiringthe manufacture of custom composite construction panels. A compositeconstruction panel design program is provided to a customer 414, 416 viaa hard copy 418, e.g., a disk containing a copy of the program, or viaelectronic access, e.g., the Internet or e-mail. The compositeconstruction panel design software is utilized by a customer on thecustomer's personal computer 414, 416. The customer designs one or morecomposite construction panels and delivers the completed design to themanufacturer 420. The design can be printed to provide a hard copy 418to the manufacturer 420. In a particular embodiment of the presentinvention, the finished design is uploaded to a central computer 406located at the manufacturer 420. In another particular embodiment,compatibility between the design program software and the software ofthe apparatus for molding a semi-continuous or continuous foamed plasticelement 408 allows the finished design specifications to be entered intothe apparatus 408 directly through a connection to the central computer.In another embodiment, the design specifications are entered manually byan apparatus operator. The design software stores and sorts the databased on particular panel design types, and identifies the mostefficient sequence for making panels. Thus, the software is usable as amanagement tool to simplify the work of the apparatus operator,including specifying what order to make the panels and how to maneuverparts of the apparatus to change from one panel design to the next. Themethod of doing business as illustrated in FIG. 40 reduces the time andcost to design and manufacture custom construction panels.

The present invention has been described with reference to specificdetails of particular embodiments thereof. It is not intended that suchdetails be regarded as limitations upon the scope of the inventionexcept insofar as and to the extent that they are included in theaccompanying claims.

1. A composite wall panel comprising: a central body, substantiallyparallelepipedic in shape, comprised of an expanded polymer matrix,having opposite faces, a top surface, an opposing bottom surface, a maleend and a female end; and two or more reinforcing embedded memberstransversely extending across the central body between said oppositefaces, having a central portion embedded in the expanded polymer matrix,a first exposed end extending from the central portion and the topsurface, and a second exposed end extending from the central portion andthe bottom surface, wherein the reinforcing embedded members include oneor more expansion holes located in the central portion of the embeddedmembers and one or more utility holes located in the first exposed endand the second exposed end; a first concrete layer placed over the topsurface encasing the first exposed end of the reinforcing embeddedmembers; and a second concrete layer placed over the bottom surfaceencasing the second exposed end of the reinforcing embedded members;wherein the central body comprises a polymer matrix that expands throughthe expansion holes; wherein the set and hardened concrete of the firstconcrete layer fuses through the utility holes in the first exposed end;wherein the set and hardened concrete of the second concrete layer fusesthrough the utility holes in the second exposed end; and wherein thereinforcing embedded members comprise an epoxy resin reinforced with oneor more fibers selected from the group consisting of carbon fibers,aramid fibers, glass fibers, metal fibers, and combinations thereof. 2.The composite wall panel according to claim 1, wherein the central bodycomprises a male end and a female end.
 3. The composite wall panelaccording to claim 1, wherein the reinforcing embedded members arelongitudinally extending within the central body along substantially theentire length thereof.
 4. The composite wall panel according to claim 1,wherein the reinforcing embedded members have a thickness of form 0.4 to10 mm.
 5. The composite wall panel according to claim 1 comprising twoor more reinforcing embedded members, wherein the distance between thereinforcing embedded members is from 10 cm to 110 cm.
 6. The compositewall panel according to claim 1, wherein the expanded polymer matrixcomprises one or more polymers selected from the group consisting ofhomopolymers of vinyl aromatic monomers; copolymers of at least onevinyl aromatic monomer with one or more of divinylbenzene, conjugateddienes, alkyl methacrylates, alkyl acrylates, acrylonitrile, and/ormaleic anhydride; polyolefins; polycarbonates; and combinations thereof.7. The composite wall panel according to claim 2, wherein the male endof the central body comprises a tongue edge and the female end of thecentral body comprises a female groove edge that facilitates a tongueand groove union between a first central body and a second central bodyto form one or more combined composite wall panels, wherein the firstand second concrete layers are continuous over at least a portion of thetop surface and bottom surface.
 8. The composite wall panel according toclaim 1, wherein the central body has a thickness measured as thedistance between the first surface and the second surface of from 2 cmto 50 cm.
 9. The composite wall panel according to claim 1, wherein thecentral body comprises openings extending along the length of thecentral body.
 10. The composite wall panel according to claim 9, whereinthe openings have a cross-sectional shape selected from the groupconsisting of round, oval, elliptical, square, rectangular, triangular,hexagonal and octagonal and a cross-sectional area of from 1 cm² to 130cm².
 11. The composite wall panel according to claim 1, wherein thepolymer matrix comprises an interpolymer of a polyolefin and in situpolymerized vinyl aromatic monomers.
 12. The composite wall panelaccording to claim 1, wherein the polymer matrix comprises carbon black,graphite or a combination thereof.
 13. The composite wall panelaccording to claim 1, wherein the central body with at least onereinforcing embedded member is made by continuously or semi-continuouslymolding a foamed plastic central body with one or more reinforcingembedded members partially embedded therein.
 14. The composite wallpanel according to claim 1, wherein the concrete is light weightconcrete.
 15. A wall comprising one or more composite wall panelsaccording to claim
 1. 16. A method of constructing a buildingcomprising: assembling the composite wall panel according to claim 1 ona generally flat surface, and lifting a first end of the composite wallpanel while a second end remains stationary resulting in orienting thewall panel to form a wall of the building.
 17. A building constructedaccording to the method of claim
 16. 18. The composite wall panelaccording to claim 1, wherein the reinforcing embedded members compriseone or more other additives selected from the group consisting ofultraviolet (UV) stabilizers, heat stabilizers, flame retardants,biocides, and combinations thereof.